Systems, methods, and controller for parallel staging of heat exchangers

Abstract

A method, controller and system that stages modulates multiple heat exchangers to optimize one or more parameters, such as heat transfer efficiency. Staging parallel heat exchangers by selectively modulating can increase individual flow velocity, reducing fouling of the heat exchangers. An example of the method includes: determining a load profile of the variable load; determining a plurality of candidate heat exchangers that have not been installed in the system that each have respective capacity for operating in parallel in a staged manner to source the variable load according to the load profile, each candidate heat exchanger having at least one respective parameter affected by the variable load according to the load profile; and calculating the at least one respective parameter for combinations of two or more of the candidate heat exchangers operating in parallel in the staged manner in the system according to the load profile.

Description

SYSTEMS, METHODS, AND CONTROLLER FOR PARALLEL STAGING OF HEAT EXCHANGERSCROSS-REFERENCE

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 755801 filed February 7, 2025 entitled SYSTEMS, METHODS, AND CONTROLLER FOR PARALLEL STAGING OF HEAT EXCHANGERS, the entire contents of which are herein incorporated by reference in to the Detailed Description, herein below.TECHNICAL FIELD

[0002] Example embodiments generally relate to heat transfer systems and heat exchangers.BACKGROUND

[0003] Heating Ventilation and Air Conditioning (HVAC) systems for a premises such as a building can contain central chilled water plants that are designed to provide air conditioning units with cold water as to reduce the temperature of the air that leaves the conditioned space before it is recycled back into the conditioned space during summer conditions. Similarly applicable for heating application where hot water from the boiler is used for heating the air in the building during winter conditions.

[0004] Chilled water plants are used to provide cold water or air for a building. Chilled water plants can comprise of active and passive mechanical equipment which work in concert to reduce the temperature of warm return water before supplying it to the distribution circuit. In chilled water plants, a heat exchanger is used to transfer heat energy between two or more circuits of circulation mediums. Similarly, a heating plant can include heat sources such as one or more boilers that provide hot water or air to thedistribution circuit, from one or more boilers or from a secondary circuit having the heating source.

[0005] Some conventional industry practices may design heating, cooling and plumbing system performance around a single point that represented the most extreme conditions or loads that a building might experience during its operating lifecycle. A difficulty with some existing systems is that, at part-load, the pumping system may be susceptible to instability, poor occupant comfort and energy and economic wastage.

[0006] The traditional selection of a pump or pumps, heat exchangers, and associated equipment for a building may result in wastage of resources and inefficient operation. Load limits for a building may vary so that the equipment (e.g. pump, boiler plant, chiller, booster, heat exchanger, air separator, or other) may not be required to operate at full capacity to service the system requirements. Further, improper equipment selection may require a repair or total replacement of the equipment to a more suitable size of equipment (e.g. pump, boiler plant, chiller, booster, heat exchanger, air separator, or other). The operation of one equipment for a building affects the performance of another equipment that is operating in the same building.

[0007] Low pressure drop on a plate heat exchanger generally results in lower turbulence of the fluids and therefore leading to a lower heat transfer efficiency.

[0008] A typical reason for designing a heat exchanger with low pressure drop is to maintain lower pump operational energy costs. However, a drawback to this traditional methodology is lowering of the heat transfer efficiency as with lower pressure drops, the flow is generally not as turbulent therefore the heat does not transfer as effectively through the plates. To compensate for the lower heat transfer efficiency caused by the decreased turbulence in the fluids, the heat transfer area of the heat exchanger requires to be increased in order to meet the heat load requirements. In the case of a plate heat exchanger, this means more plates require to be added and therefore potentially oversizing the heat exchanger. As the primary construction of heat exchangers is metal, oversizing the heat exchanger also means higher capital costs. As well, an oversized plate heat exchanger due to a lower pressure drop can lead to lower fluid velocities which along with the lowered fluid turbulence allows for particulates and scaling materials tosettle on the plate surface, resulting in fouling of the heat exchanger. As well, as a low pressure drop is designed based on a specific pump flow and head, if the flow rate changes significantly, the heat exchanger may not be able to maintain efficient heat transfer, resulting to a system underperforming, and therefore, leading to inefficient temperature control or heat recovery. If a heat exchanger has excessive pressure drop, then that means that the heat exchanger was not suitable sized and may not perform properly or efficiently.

[0009] Heat exchangers are usually selected such that all the process load is served by one heat exchanger. In variable systems, an issue that is encountered is that the flow may be significantly less than the design point. This leads to low fluid velocities in the heat exchanger.

[0010] Low fluid velocities can lead to mal distribution of flow in the heat exchanger or laminar flow, and thus leading to lowered heat transfer efficiency over time.

[0011] Low fluid velocities can also lead to quicker fouling of the heat exchanger.

[0012] It can be challenging to reduce fouling of the heat exchanger during realtime operation.

[0013] Other difficulties with existing systems may be appreciated in view of the Detailed Description of Example Embodiments, herein below.SUMMARY

[0014] An example embodiment is a controller that is configured to perform parallel staging of heat exchangers.

[0015] An example embodiment is a controller that stages modulates multiple heat exchangers to optimize one or more parameters

[0016] An example embodiment is a controller that stages modulates multiple heat exchangers to optimize heat transfer efficiency over time

[0017] An example embodiment is a controller that stages module multiple heat exchangers to optimize heat transfer efficiency over time accounting for fouling

[0018] An example embodiment is a controller that automatically cleans the heat exchanger by increase flow velocity in individual heat exchangers over time.

[0019] In an example embodiment, a process implemented by a controller includes automated valve control, sensor feedback integration, and real-time performance monitoring. By recalibrating pressure drop baselines post-cleaning while preserving initial startup values, the process ensures accurate fouling detection and efficient heat exchanger operation. The process eliminates the need for manual recalibration after cleaning cycles, improving system reliability and reducing maintenance costs. The process is applicable to both simplex and multiplex configurations and enhances operational efficiency by continuously adapting to changing system conditions.

[0020] An example embodiment is a heat transfer system, comprising: a plurality of heat exchangers in parallel configured for connection to a first fluid circuit and a second fluid circuit; a respective valve for each of the heat exchangers; and at least one controller configured to: control the respective valve to optimize at least one parameter of each of the heat exchangers.

[0021] In another example embodiment of any of the above, the at least one parameter of each of the heat exchangers includes: heat transfer efficiency; heat transfer coefficient (U); heat transfer capacity (Qc); flow value up to flow capacity; flow velocity value; pressure drop value; temperature load capacity, and / or fouling factor.

[0022] In another example embodiment of any of the above, the at least one parameter of each of the heat exchangers includes a coefficient value of each of the heat exchangers.

[0023] In another example embodiment of any of the above, the at least one parameter includes cost over part load operation, wherein the cost is based on operating cost and replacement cost.

[0024] In another example embodiment of any of the above, the controlling the respective valve is in a staged manner.

[0025] In another example embodiment of any of the above, the controlling the respective valve in the staged manner includes maximizing flow velocity for each of the plurality of heat exchangers having the respective valve that is open.

[0026] In another example embodiment of any of the above, the optimizing the at least one parameter includes optimizing the at least one parameter over time.

[0027] In another example embodiment of any of the above, the optimizing the at least one parameter over time is over a time of life of each of the heat exchangers.

[0028] In another example embodiment of any of the above, the respective valve is a respective variable control valve.

[0029] In another example embodiment of any of the above, the optimizing includes controlling at least one of the respective valve to a partially open state.

[0030] In another example embodiment of any of the above, the respective valve is a respective shutoff valve.

[0031] In another example embodiment of any of the above, the controlling the respective valve is performed during real time sourcing of a variable load.

[0032] In another example embodiment of any of the above, the controlling the respective valve includes opening only an individual one of the heat exchangers to flush a fouling of the individual one of the heat exchangers during real time sourcing of a variable load.

[0033] In another example embodiment of any of the above, the heat transfer further includes: first at least one variable control pump for providing variable flow of a first circulation medium through the first fluid circuit; and at least one flow control mechanical device for providing variable flow of a second circulation medium through the second fluid circuit, wherein the at least one controller is configured to control the first at least one variable control pump and the flow control mechanical device to perform the optimizing during real time sourcing of a variable load.

[0034] In another example embodiment of any of the above, the controlling the first at least one variable control pump is to a first flow amount during the real time sourcing ofthe variable load in order to flush a fouling of each of the plurality of heat exchangers having the respective valve that is open.

[0035] In another example embodiment of any of the above, the at least one flow control mechanical device includes second at least one variable control pump or a variable control valve.

[0036] In another example embodiment of any of the above, the at least one parameter of each of the heat exchangers includes an affect of that heat exchanger on operating cost of or pressure drop fulfillment by the first at least one variable control pump.

[0037] In another example embodiment of any of the above, the controlling the respective valve includes opening less than all of the valves at a time.

[0038] In another example embodiment of any of the above, the at least one controller is located remote to the plurality of heat exchangers.

[0039] In another example embodiment of any of the above, the plurality of heat exchangers are integrated in a heat transfer module which is configured to be connected to the first fluid circuit and the second fluid circuit.

[0040] In another example embodiment of any of the above, the at least one controller is integrated with the heat transfer module.

[0041] In another example embodiment of any of the above, the at least one controller is separate from the heat transfer module.

[0042] In another example embodiment of any of the above, the heat transfer system further includes: a first pressure sensor configured to detect pressure measurement of input to the first fluid circuit of the heat transfer module; a second pressure sensor configured to detect pressure measurement of input to the second fluid circuit of the heat transfer module; a first pressure differential sensor across the input to output of the first fluid circuit of the heat transfer module; a second pressure differential sensor across the input to output of the second fluid circuit of the heat transfer module; a first temperature sensor configured to detect temperature measurement of the input of the first fluid circuit of the heat transfer module; a second temperature sensor configuredto detect temperature measurement of the output of the first fluid circuit of the heat transfer module; a third temperature sensor configured to detect temperature measurement of the input of the second fluid circuit of the heat transfer module; a fourth temperature sensor configured to detect temperature measurement of the output of the second fluid circuit of the heat transfer module; and a respective temperature sensor to detect temperature measurement of output of each heat exchanger to each of the first fluid circuit and the second fluid circuit of the heat transfer module, wherein the at least one controller is configured to receive data indicative of measurement from the first pressure sensor, the second pressure sensor, the first pressure differential sensor, the second pressure differential sensor, the first temperature sensor, the second temperature sensor, the third temperature sensor, and the fourth temperature sensor, for the optimizing.

[0043] In another example embodiment of any of the above, the heat transfer system further includes: a first flow sensor configured to detect first flow measurement of first flow through the first fluid circuit; and a second flow sensor configured to detect second flow measurement of second flow through the second fluid circuit, wherein the at least one controller is configured to: receive data indicative of the first flow measurement and the second flow measurement from the first flow sensor and the second flow sensor, calculate a respective heat load (Q) of the first flow through the heat transfer module and the second flow through the heat transfer module from: the first flow measurement, the second flow measurement, the respective temperature measurement from the first temperature sensor, the respective temperature measure from the third temperature sensor, and the respective temperature measurement from the respective temperature sensor of the output of each heat exchanger to each of the first fluid circuit and the second fluid circuit, and wherein said optimizing is based on the respective heat load (Q) of the first flow and the respective heat load (Q) of the second flow.

[0044] In another example embodiment of any of the above, the heat transfer system further includes: at least one pressure sensor, temperature sensor, or flow sensor configured to detect measurement of the first fluid circuit and / or the second fluid circuit, wherein said optimizing is based on the measurement.

[0045] In another example embodiment of any of the above, said optimizing comprises determining that the measurement or a calculation or inference from the measurement reaches a threshold, and in response to said determining, increasing or decreasing a number of the valves to be opened.

[0046] In another example embodiment of any of the above, said optimizing comprises mapping the measurement to a number of the valves to be opened.

[0047] In another example embodiment of any of the above, the at least one pressure sensor, the temperature sensor, or the flow sensor is configured to detect measurement of at least one of the plurality of heat exchangers.

[0048] In another example embodiment of any of the above, the at least one pressure sensor, temperature sensor, or flow sensor is configured to detect measurement of a source supply or a system setpoint location.

[0049] In another example embodiment of any of the above, said optimizing comprises mapping a system variable or a system setpoint to a number of the valves to be opened.

[0050] In another example embodiment of any of the above, the system variable or the system setpoint includes head demand, flow demand, or temperature demand.

[0051] In another example embodiment of any of the above, each heat exchanger is a plate and frame counter current heat exchanger; a shell and tube heat exchange; or a gasketed plate heat exchanger.

[0052] In another example embodiment of any of the above, at least two of the heat exchangers have a different dimension and a different capacity.

[0053] In another example embodiment of any of the above, at least two of the heat exchangers have a same dimension and a same capacity.

[0054] Another example is a method for the heat transfer system as in any one of the above, the method being implemented by at least one controller and comprising: controlling the respective valve to optimize at least one parameter of each of the heat exchangers.

[0055] Another example embodiment is a method for a system having a variable load, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a plurality of candidate heat exchangers that have not been installed in the system that each have respective capacity for operating in parallel in a staged manner to source the variable load according to the load profile, each candidate heat exchanger having at least one respective parameter affected by the variable load according to the load profile; calculating the at least one respective parameter for combinations of two or more of the candidate heat exchangers operating in parallel in the staged manner in the system according to the load profile; and selecting one of the combinations of the two or more candidate heat exchangers which optimize the at least one respective parameter for the operating in parallel in the staged manner for installation in the system.

[0056] In another example embodiment of any of the above, the load profile is for flow load or temperature load.

[0057] In another example embodiment of any of the above, the method further includes: determining one or more candidate variable flow control mechanical devices for operating with the two or more candidate heat exchangers in the system based on the load profile, wherein the calculating includes calculating the at least one respective parameter for the combinations of the two or more candidate heat exchangers operating in the staged manner with the one or more candidate variable flow control mechanical devices.

[0058] In another example embodiment of any of the above, the one ore more candidate variable flow control mechanical devices comprise one or more variable control pumps or one or more pressure independent control valves.

[0059] In another example embodiment of any of the above, the at least one respective parameter of each of the two or more candidate heat exchangers includes an affect of those two or more candidate heat exchangers on operating cost of or pressure drop fulfillment by the one or more variable control pumps.

[0060] In another example embodiment of any of the above, the method further includes determining a design setpoint of the system, wherein the design setpoint affectsthe at least one parameter, wherein the calculating is further based on the design setpoint.

[0061] In another example embodiment of any of the above, the design setpoint is flow and head.

[0062] In another example embodiment of any of the above, the two or more candidate heat exchangers of the one of the combinations that are selected have different of the respective capacity and a different respective dimension.

[0063] In another example embodiment of any of the above, the two or more candidate heat exchangers of the one of the combinations that are selected have a same of the respective capacity and a same respective dimension.

[0064] In another example embodiment of any of the above, the method further includes performing the operating in the system of the one of the combinations of the two or more candidate heat exchangers that are selected for the installation in the system.

[0065] In another example embodiment of any of the above, said performing the operating of the one of the combinations that is selected in the staged manner is by controlling a respective valve for the two or more candidate heat exchangers that are selected.

[0066] In another example embodiment of any of the above, said performing the operating comprises mapping a system variable or a system setpoint to a number of the two or more candidate heat exchangers of the one of the combinations that are selected to be opened.

[0067] In another example embodiment of any of the above, the system variable or the system setpoint includes head demand, flow demand, or temperature demand.

[0068] In another example embodiment of any of the above, the at least one respective parameter of each of the two or more candidate heat exchangers in the combinations includes: heat transfer efficiency; heat transfer coefficient (U); heat transfer capacity (Qc); flow value up to flow capacity; flow velocity value; pressure drop value; temperature load capacity, and / or fouling factor.

[0069] In another example embodiment of any of the above, the at least one respective parameter includes cost over part load operation, wherein the cost is based on operating cost and replacement cost.

[0070] In another example embodiment of any of the above, the optimizing the at least one respective parameter includes optimizing the at least one respective parameter over time.

[0071] In another example embodiment of any of the above, the optimizing the at least one respective parameter over time is over a time of life of each of the two or more candidate heat exchangers.

[0072] In another example embodiment of any of the above, the two or more candidate heat exchangers are integrated in a heat transfer module.

[0073] In another example embodiment of any of the above, the calculating is performed using a model or a machine learning model.

[0074] In another example embodiment of any of the above, the calculating of the respective combination is based on initial cost and operating cost over a payback period.

[0075] In another example embodiment of any of the above, the calculating of the respective combination includes iteratively calculating different combinations.

[0076] In another example embodiment of any of the above, the selecting is received through a graphical user interface.

[0077] Another example embodiment is a method performed by at least one controller to perform any one of the above.

[0078] Another example embodiment is a system, heat transfer system, or building system, comprising at least one controller for performing the method of any one of the above.

[0079] Another example embodiment is a non-transitory computer readable medium having instructions stored thereon executable by at least one controller for performing the method of any one of the above.BRIEF DESCRIPTION OF THE DRAWINGS

[0080] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments, and in which:

[0081] Figure 1A illustrates a graphical representation of a building system, illustrated as a chilled water plant for providing cold water to a building, to which example embodiments may be applied.

[0082] Figure 1 B illustrates a graphical representation of further aspects of the chilled water plant shown in Figure 1A.

[0083] Figure 1 C illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower, with parallel load sharing.

[0084] Figure 1 D illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower, with load sharing.

[0085] Figure 1 E illustrates a graphical representation of an example heating plant.

[0086] Figure 1 F illustrates a graphical representation of an example chilled water plant having a direct cooling loop.

[0087] Figure 1 G illustrates a graphical representation of an example heating plant having a district heating loop.

[0088] Figure 1 H illustrates a graphical representation of an example heating plant for heating potable water.

[0089] Figure 11 illustrates a graphical representation of an example building system for waste heat recovery.

[0090] Figure 1 J illustrates a graphical representation of an example building system for geothermal heating isolation.

[0091] Figure 2A illustrates a graphical representation of a heat exchanger, in accordance with an example embodiment.

[0092] Figure 2B illustrates a perspective view of an example heat transfer module with two heat exchangers, in accordance with an example embodiment.

[0093] Figure 2C illustrates a perspective view of an example heat transfer module with three heat exchangers, in accordance with an example embodiment.

[0094] Figure 2D illustrates a partial breakaway view of contents of the heat transfer module of Figure 2C.

[0095] Figure 2E illustrates a perspective view of an example heat transfer system that includes the heat transfer module of Figure 2C and two dual control pumps.

[0096] Figure 3A illustrates a graphical representation of network connectivity of a heat transfer system, having local setup.

[0097] Figure 3B illustrates a graphical representation of network connectivity of a heat transfer system, having remote setup.

[0098] Figure 4A illustrates a graph of an example heat load profile for a load such as a building.

[0099] Figure 4B illustrates a graphical user interface for configuring the load profile of Figure 4A, in accordance with an example embodiment.

[0100] Figure 4C illustrates a graph of an example flow load profile for a load such as a building.

[0101] Figure 4D illustrates a graphical user interface for configuring the load profile of Figure 4C, in accordance with an example embodiment.

[0102] Figure 5A illustrates a graph of system head versus flow, having operation ranges of one or more heat exchangers for a heat transfer system.

[0103] Figure 5B illustrates a graph of cooling capacity versus flow, having operation ranges for one or more heat exchangers for a heat transfer system.

[0104] Figure 5C illustrates a graph of heating capacity versus flow, having operation ranges for one or more heat exchangers for a heat transfer system.

[0105] Figure 6A illustrates an example graph of heat transfer coefficient value (U-Value) versus flow of a clean heat exchanger.

[0106] Figure 6B illustrates an example graph of heat transfer coefficient value (U-Value) versus flow of a heat exchanger.

[0107] Figure 7A illustrates a flow diagram of an example method for automatic maintenance on a heat exchanger, in accordance with an example embodiment.

[0108] Figure 7B illustrates a flow diagram of an example method for determining that one or more control pumps are to perform maintenance on the heat exchanger.

[0109] Figure 7C illustrates a flow diagram of an alternate example method for determining that one or more control pumps are to perform maintenance on the heat exchanger.

[0110] Figure 7D illustrates a flow diagram of another alternate example method for determining that one or more control pumps are to perform maintenance on the heat exchanger.

[0111] Figure 8A illustrates a graph of simulation results of brake horsepower versus time of a control pump operating through various heat exchangers having various foul factors, including one heat exchanger having automatic maintenance in accordance with an example embodiment.

[0112] Figure 8B illustrates a graph of fouling factor versus flow velocity for specific types of impurities.

[0113] Figure 9 illustrates an example method for selecting two or more heat exchangers for operation in the building system, in accordance with an example embodiment.

[0114] Similar reference numerals may have been used in different figures to denote similar components.DETAILED DESCRIPTION

[0115] Example embodiments generally relate to heat transfer systems and heat exchangers.

[0116] At least some example embodiments relate to processes, process equipment and systems in the industrial sense, meaning a process that outputs product(s) (e.g. hot water, cool water, air) using inputs (e.g. cold water, fuel, air, etc.). In such systems, a heat exchanger or heat transfer system can be used to transfer heat energy between two or more circuits (fluid paths) of circulation mediums. In some systems, an air separator can be used to remove air (and sometimes dirt) from the circulation medium.

[0117] At least some example embodiments relate to equipment in a system such as an HVAC system, temperature control system, heat transfer system, hydronic system, or flow control system.

[0118] Many building systems do not operate at full load (duty load). In an example embodiment, a controller can be configured for operation and / or facilitating selection of equipment for operation in the building system.

[0119] Figure 1A illustrates an example building system 100 such as a chilled water plant, in accordance with an example embodiment. In an example, the building system 100 is a HVAC building system. As shown in Figure 1A, the building system 100 can include, for example: one control pump 102a for load, one chiller 120, one control pump 102b for source, an air separator 132, and two cooling towers 124. The chiller 120 can include a heat exchanger 118. The heat exchanger 118 can include sensors 150. The heat exchanger 118 defines a first fluid path 204 (of a first fluid circuit) for a first circulation medium, and a second fluid path 206 (of a second fluid circuit) for a second circulation medium. In an example embodiment, more or fewer numbers of device can exist within each equipment category. Other types of equipment, rotary devices, and flow control devices (e.g. valves) may be included in the building system 100.

[0120] The building system 100 can be used to source a building 104 (as shown), campus (multiple buildings), premises, district, vehicle, plant, generator, heat exchanger, or other suitable infrastructure or load, with suitable adaptations. The control pump 102a may include one or more respective pump devices 106a (one shown here, whereas two pump devices for a single control pump 102a are illustrated in Figure 2E) and a control device 108a for controlling operation of the pump device 106a. The control pump 102b can have a variably controllable motor, and can include a pump device 106b and a control device 108b. The particular circulation medium may vary depending on the particular application, and may for example include glycol, water, air, fuel, and the like. The chiller 120 can include at least a condenser and an evaporator, for example, as understood in the art. The condenser of the chiller 120 collects unwanted heat through the circulation medium before the circulation medium is sent to the cooling towers 124. The chiller 120 itself is (or is part of) a heat exchanger, and examples embodiments that refer to a heat exchanger can be applied to the chiller 120, as applicable. The evaporator of the chiller 120 is where the chilled circulation medium is generated, and the chilled circulation medium leaves the evaporator and is flowed to the building 104 by the control pump 102a. Each cooling tower 124 can be dimensioned and configured to provide cooling by way of evaporation, and can include a respective fan, for example. Each cooling tower 124 can include one or more cooling tower cells, in an example.

[0121] The building system 100 can be configured to provide air conditioning units of the building 104 with cold water to reduce the temperature of the air that leaves the conditioned space before the air is recycled back into the conditioned space. The building system 100 can comprise of active and passive mechanical equipment which work in concert to reduce the temperature of warm return water before supplying it to the distribution circuit.

[0122] Referring to Figure 1B, the building system 100 may include a heat exchanger 118 which is an interface in thermal communication with a secondary circulation system, for example via the chiller 120 (Figure 1A), ambient, or a temperature source. The heat exchanger 118 can be placed in various positions in the building system 100 of Figure 1B. The air separator 132 can be placed in various positions in the building system 100 of Figure 1B, and is typically positioned upstream of the control pump 102a.The building system 100 may include one or more loads 110a, 110b, 110c, 110d, wherein each load 110a, 110b, 110c, 110d may be a varying usage requirement based on requirements of an air conditioner, HVAC, plumbing, etc. Each 2-way valve 112a, 112b, 112c, 112d may be used to manage the flow rate to each respective load 110a, 110b, 110c, 110d. In some example embodiments, as the differential pressure across the load decreases, the control device 108a responds to this change by increasing the pump speed of the pump device 106a to maintain or achieve the output setpoint (e.g. pressure or temperature). If the differential pressure across the load increases, the control device 108a responds to this change by decreasing the pump speed of the pump device 106a to maintain or achieve the setpoint. In some example embodiments, an applicable load 110a, 110b, 110c, 110d can represent cooling coils to be sourced by the circulation medium the chiller 120, each with associated valves 112f, 112b, 112c, 112d, for example. In some examples, an applicable load 110a, 110b, 110c, 110d can represent fan coils that each include a cooling coil and a controllable fan (not shown) that blows air across the coiling coils. In some examples, the fan has a variably controllable motor to control temperature in the region to be cooled. In other examples, the fan has a binary controllable motor (e.g., only on state or off state) to control temperature in the region to be cooled. The control devices 108a and the control valves 112a, 112b, 112c, 112d can respond to changes in the chiller 120 by increasing or decreasing the pump speed of the pump device 106a, or variably controlling an amount of opening or closing of the control valves 112a, 112b, 112c, 112d, or control of the fans, to achieve the specified output setpoint.

[0123] In Figure 1A, the control pump 102b (more than one control pump is possible) is used to provide flow control from the cooling towers 124 to the chiller 120 (which can include the heat exchanger 118). In various examples, the control pump 102b can be used to control flow from a cooling or heating source to the heat exchanger 118. In some examples, the heat exchanger 118 is separate from the chiller 120. In other examples, the chiller 120 is integrated with the heat exchanger 118. In some examples, the heat exchanger 118 is integrated with one or both control pumps 102a, 102b (e.g., see Figure 2E). In other examples, the heat exchanger 118 is separated from the control pumps 102a, 102b using piping, fittings, intermediate devices, etc. The control pumps102a, 102b can be referred to as variable control pumps. The control pumps 102a, 102b are variable flow control mechanical devices. Other types variable flow control mechanical devices can be used in other example embodiments, such as variable control valves or pressure independent control valves (PICVs). In an example, not shown here, the secondary circulation system sourced by the control pump 102b can also include a respective air separator 132.

[0124] Referring to Figure 1 B, the output properties of each control pump 102a, 102b can be controlled to, for example, achieve a temperature setpoint or pressure setpoint at the combined output properties represented or detected by external sensor 114, shown at the load 110d at one point of the building 104 (e.g., the highest point in this example). The external sensor 114 represents or detects the aggregate or total of the individual output properties of all of the control pumps 102a, 102b at the load, in one example, flow and pressure. Information on flow and pressure local to the control pump 102a, 102b can also be represented or detected by a respective sensor 130, in an example embodiment. The external sensor 114 can be used to detect temperature and heat load (Q) in example embodiments. Heat load (Q) can refer to a hot temperature load or a cold temperature load. In an example, the external sensor 114 for temperature and heat load can be placed at each load (110a, 110b, 110c, 11 Od), or one external sensor 114 is placed at the highest point at the load 110d. Other example operating parameters are described in greater detail herein.

[0125] One or more controllers 116 (can be generally denoted controller 116 or controllers 116), which can include one or more processors, may be used to coordinate the output (e.g. temperature, pressure, and flow) of some or all of the devices of the building system 100. The controllers 116 can include a main centralized controller in some example embodiments, and / or can have some of the functions distributed to one or more of the devices in the overall system of the building system 100 in some example embodiments. In an example embodiment, the controllers 116 are implemented by a processor which executes instructions stored in memory. In an example embodiment, the controllers 116 are configured to control or be in communication with the loads (110a, 110b, 110c, 110d), the valves (112a, 112b, 112c, 112d), the control pumps 102a, 102b, the heat exchanger 118, and other equipment and devices.

[0126] Referring again to Figures 1 A and 1 B, in some example embodiments, the building system 100 can represent a heating circulation system (“heating plant”), with suitable adaptation. The heating plant may include a heat exchanger 118 which is an interface in thermal communication with a secondary circulation system, such as a boiler system. Instead of a chiller 120, the boiler system can include one or more boilers 140 (not shown here). In an example, control valves 112a, 112b, 112c, 112d manage the flow rate to heating elements (e.g., loads 110a, 110b, 110c, 110d). The control devices 108a, 108b and the control valves 112a, 112b, 112c, 112d can respond to changes in the heating elements (e.g., loads 110a, 110b, 110c, 110d) and the boiler system by increasing or decreasing the pump speed of the pump device 106a, or variably controlling an amount of opening or closing of the control valves 112a, 112b, 112c, 112d, to achieve the specified output setpoint (e.g., temperature or pressure). In some examples, the one or more boilers 140 is separate from the heat exchanger 118. In other examples, the one or more boilers 140 is integrated with the heat exchanger 118. In other examples, other heat sources or cooling sources can be used to source the secondary circulation system.

[0127] Each control device 108a, 108b can be contained in a Pump Controller card 226 (“PC card”) that is integrated within the respective control pump 102a, 102b. A controller (with communication device) of the heat exchanger 118 can be contained in a Heat exchanger card 222 (“HX card”) that is integrated within the heat exchanger 118. In an example, the PC card 226 can be a tablet style device that includes a touch screen, processor, and communication subsystem, that can be stand alone manufactured and then integrated into the respective control pump 102a, 102b. The HX card 222 is integrated with heat exchanger 118, and can be a similar tablet style device as the PC card 226 having a touch screen 228 in some examples, and in some examples does not have the touch screen 228. In an example, the PC card 226 can be the control device 108a, 108b of the control pump 102a, 102b (Figure 1 A).

[0128] Figure 1 C illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower 124, with parallel load sharing, in accordance with an example embodiment. In this example, the cooling tower 124 sources the chiller 120 and the heat exchanger 118 in parallel. Theload 110a, 110b, 110c, 110d is an air conditioner load that is sourced by the chiller 120 and the heat exchanger 118 in parallel.

[0129] In the configuration of Figure 1 C, the supply flow is usually run at full speed. Since the cooling tower 124 operation is relatively cheap compared to running a chiller 120, running the maximum flow through the cooling tower 124 is preferred. In cases where the cooling tower 124 is used in part loads, then controlling Tload, supply or using a Maximize Source Side Delta T with constant temperature approach and constant load side Delta T is recommended to ensure that the load side is getting their design temperatures. To get additional savings, the user can define the minimum approach between Tsource, in and Tload, out using the Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. An example approach temperature of 1 F (or applicable delta in K) can be used so that pump energy is not consumed if additional heat exchange is too low.

[0130] Figure 1 D illustrates a graphical representation of another example chilled water plant, having a waterside economizer with a dedicated cooling tower 124, with load sharing, in accordance with an example embodiment. The cooling tower 124 sources the heat exchanger 118. The heat exchanger 118 provides cooled circulation medium to the chiller 120. The chiller provides further temperature reduction and sources the load 110a, 110b, 110c, 11 Od, which is an air conditioner load. The heat exchanger 118 can also directly source the load 110a, 110b, 110c, 110d by way of chiller bypass piping, as shown.

[0131] Since the chiller 120 uses the most energy in the building system 100, it is advantageous for the control pump 102b to run full speed. In cases where the cooling tower 124 is used in part loads, then controlling Tload, supply or using a Maximize Source Side Delta T with constant temperature approach and constant load side Delta T is recommended to ensure that the load side is getting their design temperatures. To get additional savings, the user can define the minimum approach between Tsource, in and Tload, out using a Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. An approach temperature of 1 F (or applicable delta in K)is recommended so that pump energy is not consumed if additional heat exchange is too low.

[0132] An input on the pump is reserved that allows the building system 100 to switch between load sharing and running the cooling tower 124 by itself.

[0133] In another example, not shown here, a vehicle system can include a similar system for an air conditioner of a vehicle, in accordance with an example embodiment. The air conditioner, that includes a compressor and condenser, circulates a coolant through the heat exchanger 118 in order to cool ambient air or recirculated air to the passenger interior of the vehicle. The cool ambient air can pass through bypass piping or valves to bypass the heat exchanger 118 in some examples.

[0134] Figure 1 E illustrates a graphical representation of an example heating plant, in accordance with an example embodiment. The heating plant includes a boiler 140 that sources the heat exchanger 118. The heat exchanger 118 transfers heat energy to the loads 110a, 110b, 110c, 110d, which can be parallel loads that are perimeter heating units.

[0135] When the boiler 140 is a condensing boiler, the efficiency of the boiler 140 increases as the return water temperature is lower. To attain the lowest return temperature, the source side flow should be minimized without affecting the load side too adversely. The recommended control methods would be to Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out.

[0136] For non-condensing boilers, the efficiency does not vary much with return temperature, therefore, the recommend method is Maximize Source Side Delta T with constant temperature approach and constant load side Delta T.

[0137] Figure 1 F illustrates a graphical representation of an example chilled water plant having a direct cooling loop, in accordance with an example embodiment. The chiller 120 sources the heat exchangers 118 that are in parallel. The chiller 120 includesa condenser and an evaporator. Each heat exchanger 118 transfers heat energy for providing cooled circulation medium to each respective load 110a, 110b, 110c, 110d. The loads 110a, 110b, 110c, 110d can represent air handling units on a respective floor or zone.

[0138] In the configuration of Figure 1 F, the chiller 120 controls the supply temperature, which can be based on ASHRAE (RTM) 90.1. For the chiller 120, a higher return temperature leads to more efficient operation (approximately 2% efficiency improvement per 1 F higher, or equivalent delta K). The recommended control method is Tload, out control or Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out.

[0139] A similar configuration of Figure 1 F can be used for a direct heating loop, in other examples. For condensing boilers 140, the recommended control methods would be Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out. For non-condensing boilers 140, the efficiency does not vary much with return temperature, therefore, the recommend method is Maximize Source Side Delta T with constant temperature approach and constant load side Delta T.

[0140] Figure 1 G illustrates a graphical representation of an example heating plant having a district heating loop, in accordance with an example embodiment. The district can be multiple buildings 104. A boiler 140 is used to source the heat exchangers 118 that are in parallel, for example one heat exchanger 118 per respective building 104. Each heat exchanger 118 transfers heat energy to a respective load 110a, 110b, 110c, 110d for each building 104. A similar configuration can be used for a district cooling loop, in other examples.

[0141] In this configuration, the source side control pump 102b is sometimes replaced by a smart energy valve when the application requires. An optimization methodis to return the highest temperature on the source side in cooling and return the lowest source side temperature in heating. The recommend control method is Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. Further energy efficiency improvements can be obtained using Maximize Source Side Delta T with variable temperature approach and variable load side Delta T if the user is flexible with varying Tload, out.

[0142] Figure 1 H illustrates a graphical representation of an example heating plant for heating potable water, in accordance with an example embodiment. The boiler 140 can be a hot water boiler that sources the heat exchanger 118. The heat exchanger 118 transfers heat energy potable water to a hot water storage tank 142, for sourcing heated potable water to the load 110a, 110b, 110c, 110d, which can be faucets, taps, etc. In this configuration the hot water storage tank 142 would usually be required to be kept at a constant temperature. An example control method would be to control Tload, out.

[0143] Figure 11 illustrates a graphical representation of an example building system 100 for waste heat recovery, in accordance with an example embodiment. A heat source such as a computer room has heat removed by way of a circulation medium to the heat exchanger 118, in order to cool the computer room. The heat exchanger 118 then transfers the heat to any water to be preheated. In this mode the heat recovery is to be used as much as possible. An example method is to maximize Delta T between Tload, in and Tload, out. Another example method is to control Tsource, out for a desired return temperature. Note that reference to “source” and “load” may be switched here, depending on the particular perspective.

[0144] In another example, a vehicle system can include a similar system for waste heat recovery, in accordance with an example embodiment. A heat source such as an engine of a vehicle has heat removed by way of a circulation medium to the heat exchanger 118, in order to cool the engine. The heat exchanger 118 then transfers the heat to air of the air circulation system to the passenger interior of the vehicle.

[0145] Figure 1 J illustrates a graphical representation of an example building system 100 for geothermal heating isolation, in accordance with an example embodiment. A heat source such as geothermal is used to heat a circulation medium tothe heat exchanger 118. The heat exchanger 118 then transfers the heat to provide hot, clean water to the load(s) 110a, 110b, 110c, 110d. In this configuration, it is desired that as much heat is transferred without leaving Tsource, out too cold as it can harm the living organisms in the vicinity. In this case, Tsource, out can be controlled with a minimum temperature set.

[0146] If any of the four temperature sensors which measure the port inlet temperatures on the hot and cold side of the heat exchanger 118 are not available or out of range, then the pump controls on the source side control pump 102b can default to constant speed and the pump controls on the load side control pump 102a can default to so-called sensorless mode, as described herein.

[0147] Figure 2A illustrates a graphical representation of the heat exchanger 118, in accordance with an example embodiment. The heat exchanger 118 is a plate type counter current heat exchanger in an example. The heat exchanger 118 includes a frame 200 that is a sealed casing. The heat exchanger 118 defines a first fluid path 204 (of a first fluid circuit) for a first circulation medium, and a second fluid path 206 (of a second fluid circuit) for a second circulation medium. The first fluid path 204 is a source fluid path and the second fluid path 206 is a load fluid path. The first fluid path 204 is not in fluid communication with the second fluid path 206. The first fluid path 204 is in thermal contact with the second fluid path 206. The first fluid path 204 can flow in an opposing flow direction (counter current) to the second fluid path 206. In an example, the heat exchanger 118 is a brazed plate heat exchanger (BPHE). A plurality of brazed plates 202 are parallel plates that facilitate heat transfer between the first fluid path 204 and the second fluid path 206. The first fluid path 204 and the second fluid path 206 flow between the brazed plates 202, typically the first fluid path 204 and the second fluid path 206 are in alternating fluid paths of the brazed plates 202. The plurality of brazed plates 202 are dimensioned with braze patterns for causing turbulence to promote heat transfer between the first fluid path 204 and the second fluid path 206. Turbulent flow in the heat exchanger 118 is increased (decreases probability of turbulent flow), and as a result there is a higher pressure drop across the heat exchanger 118. Turbulent flow promotes loosing of fouling on the braze patterns of the brazed plates 202. For a smaller heat exchanger 118 (which uses less material), a higher pressure drop increases turbulentflow (decreases probability of turbulent flow) but also requires higher pump energy consumption. In other examples, the heat exchanger 118 is a shell and tube (S&T) type heat exchanger, or a gasketed plate heat exchanger (PHE)).

[0148] The load side is the side that is connected to the load requiring heat such as a building or room. Variable flow through the load side is controlled by the control pump 102a. The source side is connected to the source of heat that is to be transferred such as the chiller 120, boiler 140, or district source. Variable flow through the source side is controlled by the control pump 102b. There are two conventions that can be used to notate parameters in heat transfer loops. The first convention, parameters such as temperature and flow are taken with reference to the heat exchanger 118. That is, for example, the water temperature going in to the heat exchanger 118 from the source side is called Tsource, in. The water temperature going out of the heat exchanger 118 from the source side is called Tsource, out.

[0149] An alternate convention is that parameters are notated such that, on the source side, the supply is taken as the fluid provided from the source to the heat exchanger 118 and the return is taken as the fluid returned to the source. For the load side, the supply is taken as the fluid provided to the load and the return is the fluid returned from the load. This is taken from chiller and fan coil conventions. For the purpose of calculations, examples herein will mainly refer to the first convention referencing the in and out looking from the heat exchanger 118.

[0150] In example embodiments, any or all of control pumps 102a, 102b can be replaced with, or used in combination with, other types of variable flow control mechanical devices such as variable control valves or pressure independent control valves (PICVs). For example, in example embodiments, rather than the load side control pump 102b, another type of flow control mechanical device such as a variable control valve is used instead of the control pump 102b. The source side can be connected to the source of heat that is to be transferred such as the chiller 120, boiler 140, or district source, which may have their own pumps (not necessarily controllable by the controllers 116) and provide a constant or variable flow to the heat exchanger 118. The variable flow on the source side of the heat exchanger 118 is controlled by the variable control valve.Information detected by one or more of the described sensors can be used to determine the variable control of the variable control valve (e.g., the amount of opening), to achieve the desired amount of flow. For example, municipal flow has a variable source pressure to the heat exchanger 118, and the variable control valve can be used to control the flow to the heat exchanger.

[0151] In an example, not shown, the variable control valve includes a controller and a variable valve that is controlled by the controller. The controller of the variable control valve can be configured for communication with the controllers 116, for example to receive instructions on the variable amount of opening or flow, and for example to send the current status of the variable amount of opening or flow. The variable control valve can include a variably controllable ball valve in some examples. Other example variable control valves include cup valves, gear valves, screw valves, etc. The variable control valve can include onboard sensors, and may perform self-adjustment, monitoring and control using its controller. The variable control valve can be pressure independent in some examples. The variable control valve can be a 2-way variable control valve in some examples.

[0152] The frame 200 of the heat exchanger 118 can include four ports 208, 210, 212, 214, as shown in Figure 2A. Port 208 is for Source, In or Source, Supply. Port 210 is for Source, Out or Source, Return. Port 212 is for Load, Out or Load, Supply. Port 214 is for Load, In or Load, Return. In an example, the frame 200 is an integrated sealed casing that cannot be disassembled, because maintenance is performed by way of flushing through the ports 208, 210, 212, 214.

[0153] Various sensors can be used to detect and transmit measurement of the heat exchanger 118. The sensors can include sensors that are integrated with the heat exchanger 118, including sensors for: Temperature Source, In (TSource, In) sensor 150a; Temperature Source, Out (TSource, In) sensor 150b; Temperature Load, Out (TLoad, Out) sensor 150c; Temperature Load, In (TLoad, In) sensor 150d; Differential Pressure between Source, In and Source, Out sensor 150e; Differential Pressure between Load, In and Load, Out sensor 150f ; Pressure at Source, In sensor 150g;Pressure at Load, In sensor 150h. More orfewerof the sensors can be used in variousexamples, depending on the particular parameter or coefficient being detected or calculated, as applicable. In some examples, the sensors include flow sensors for: Flow, source (Fsource) sensor 150i; and Flow, load (Fload) sensor 150j, which are typically external to the heat exchanger 118, and can be located at, e.g., the control pump 102a, 102b, or the external sensor 114, or the load 110a, 110b, 110c, 110d.

[0154] Baseline measurement from the sensors is stored to memory for comparison with subsequent real-time operation measurement from the sensors. The baseline measurement can be obtained by factory testing using a testing rig, for example. In some examples, the baseline measurement can be obtained during real-time system operation.

[0155] Example embodiments include a heat transfer module that can include one or more heat exchangers 118 within a single sealed casing (frame 200), wherein Figure 2B illustrates a heat transfer module 220 with two heat exchangers 118 and Figures 2C and 2D illustrate a heat transfer module 230 with three heat exchangers 118.

[0156] Figure 2E illustrates a heat transfer system 240 that includes the heat transfer module 230 and control pumps 102a, 102b. In examples, the heat transfer module can include one, two, three or more heat exchangers 118 within the single sealed casing (frame 200). The heat transfer system 240 provides a reliable and optimized heat transfer solution comprised of heat exchanger(s) 118 and control pumps 102a, 102b by providing an optimized heat transfer system solution rather than providing equipment sized for duty conditions only. The heat transfer system 240 can be used for liquid to liquid HVAC applications with typical applications in residential, commercial, industrial and public buildings, district heating or cooling, etc. Applications include cooling, heating, water side economizer (e.g., cooling tower), condenser isolation (e.g., lake, river, or ground water), district heating and cooling, pressure break, boiler heating, thermal storage, etc. The heat transfer system 240 can be shipped as a complete package or optionally shipped in modules that can be quickly assembled on site.

[0157] Figure 2B illustrates a perspective view of the heat transfer module 220 with two heat exchangers 118a, 118b, in accordance with an example embodiment. The heat transfer module 220 includes the HX card 222 for receiving measurement from thevarious sensors of the heat transfer module 220, determining that maintenance is required on the heat transfer module 220, and communicating that maintenance is required to the controllers 116 or the control pumps 102a, 102b. Shown are ports 208, 210, 214, note that port 212 is not visible in this view in Figure 2B. A touch screen 228 can be used as a user interface for user interaction with the respective heat transfer module 220. The touch screen 228 can be integrated with the HX card 222, for example, in a tablet computer style device.

[0158] Each heat exchanger 118a, 118b can have one or more respective shutoff valves 224 that are controllable by the HX card 222. Therefore, each heat exchanger 118a, 118b within the heat transfer module 220 is selectively individually openable or closable by the HX card 222. In the examples shown, there are four shutoff valves 224 across each heat exchanger 118a, 118b, for example, one respective shutoff valve 224 for each of Source, In, Source, Out, Load, In, and Load, Out. Fewer respective shutoffs valves 224 may be used to control flow through the source and load, as would be appreciated, such as one respective shutoff valve 224 for either of Source, In and Source, Out and one respective shutoff valve 224 for either of Load, In and Load, Out.

[0159] The various sensors can be used to detect and transmit measurement of parameters of the heat transfer module 220. The sensors can include temperature sensors for Temperature Source, In (TSource, In); Temperature Source, Out (TSource, In); Temperature Load, Out (TLoad, Out); Temperature Load, In (TLoad, In). The temperature sensors can further include temperature sensors, one each for respective Temperature output of the source and load fluid path of each heat exchanger 118a, 118b (four total in this example). Therefore, eight total temperature sensors can be used in the example heat transfer module 220.

[0160] The sensors can also include sensors for: Differential Pressure between Source, In and Source, Out; Differential Pressure between Load, In and Load, Out;Pressure at Source, In; Pressure at Load, In. More or fewer of the sensors can be used in various examples, depending on the particular parameter or coefficient being detected or calculated, as applicable. Such sensors can be contained within the sealed casing (frame200). In some examples, the sensors include flow sensors for: Flow, source (Fsource); and Flow, load (Fload), which are typically external to the heat transfer module 220.

[0161] Figure 2C illustrates a perspective view of the heat transfer module 230 with three heat exchangers 118a, 118b, 118c, in accordance with an example embodiment. Figure 2D illustrates a partial breakaway view of contents of the heat transfer module 230, shown without the frame 200. As can be seen in Figure 2D, the plurality of brazed plates 202 of each of the heat exchangers 118a, 118b, 118c are oriented vertically.

[0162] The heat transfer module 220 includes the HX card 222 for receiving measurement from the various sensors of the heat transfer module 220, determining that maintenance is required on the heat transfer module 220, and communicating that maintenance is required to the controllers 116 or the control pumps 102a, 102b. Shown are ports 208, 210, 214, note that port 212 is not visible in this view. The various sensors can be used to detect and transmit measurement of parameters of the heat transfer module 230, with such sensors described above in relation to the heat transfer module 220 (Figure 2B) having the two heat exchangers 118a, 118b. For example, ten total temperature sensors can be used in the example heat transfer module 230, e.g., one for each port 208, 210, 212, 214 (four total), one for each output of each heat exchanger 118a, 118b, 118c of the source path (three total), and one for each output of each heat exchanger 118a, 118b, 118c of the load path (three total).

[0163] Figure 2E illustrates a perspective view of an example heat transfer system 240 that includes the heat transfer module 230 of Figure 2C and two control pumps 102a, 102b. The control pumps 102a, 102b are each dual control pumps that each have two pump devices in a single casing, as shown. A dual control pump allows for redundancy, standby usage, pump device efficiency, coordinated control, etc. The dual control pump can have two separate PC cards 226 in some examples. A similar configuration can be used for the heat transfer module 220 of Figure 2B or a single heat exchanger 118 as in Figure 2A. As shown in Figure 2E, control pump 102a is connected to port 212 for Load, Out or Load, Supply. Control pump 102b is connected to port 208 for Source, In or Source, Supply. In other examples, the control pumps 102a, 102b are not directlyconnected to each port 212, 208 but are rather upstream or downstream of each port 212, 208, and connected through intermediate piping, or other intermediate devices such as strainers, in-line sensors, valves, pressure independent control valves (PICVs), fittings, tubing, suction guides, boilers, or chillers.

[0164] The heat transfer module 230 has the dedicated HX card 222 with WIFI communication capabilities. The HX card 222 can be configured to store a heat transfer performance map of each heat exchanger 118a, 118b, 118c in the heat transfer module 230, based on factory testing. The HX card 222 can poll data from the ten temperature sensors, two pressure sensors, and two differential pressure sensors. The HX card 222 can also poll flow measurement data from the two control pumps 102a, 102b. If the control pumps 102a, 102b are nearby and able to communicate via WIFI (via PC card 226), then data is polled directly from the control pumps 102a, 102b, otherwise flow measurement data is collected using wired connection or through the Local Area Network. The control pumps 102a, 102b can receive data from the HX card 222 and show, on the pump display screen, the inlet and outlet temperature of the fluid that the control pump 102a, 102b is pumping and the differential pressure across the heat transfer module 230.

[0165] The various sensors allow the controllers 116 to calculate heat exchanged in real time based on the flow measurement (determined by the control pumps 102a, 102b or external sensor 114) and temperatures on each side of the heat transfer module 230. Additionally, for heat transfer modules with two or three heat exchangers 118, each branch on the outlet connection can have a temperature sensor to allow fouling / clogging prediction in each individual heat exchanger 118. For each heat exchanger 118, data collected by the HX card 222 and pump PC cards 226 can be used to calculate overall heat transfer coefficient (U value) in real time and compare that with the overall clean heat transfer coefficient (llclean) to predict fouling and need for maintenance I cleaning. The collected data will be used to calculate total heat transfer in real time and optimized system operation to minimize energy costs (for pumping and on the source) while meeting load requirements. Internet connectivity will be achieved through the dedicated HX card 22 and pump PC card 226. Data is uploaded to the Cloud 308 for data logging, analysis, and control.

[0166] Suction guides (not shown) can be integrated in the heat transfer module 220, 230 with a strainer having a #20 grade (or greater) standard mesh. In an example, the suction guide is a multi-function pump fittings that provide a 90° elbow, guide vanes, and an in-line strainer. Suction guides reduce pump installation cost and floor space requirements. If the suction guide is not available, then a Y-Strainer with the proper mesh can be included. Alternatively, a mesh strainer can be installed on the source side.

[0167] Figure 3A illustrates a graphical representation of network connectivity of a heat transfer system 300, having local system setup. The heat transfer system 300 includes a Building Automation System (BAS) 302 that can include the controllers 116 (Figures 1A and 1B). The BAS 302 can communicate with the control pumps 102a, 102b and the heat transfer module 220 by a router 306 or via short-range wireless communication. A smart device 304 can be in communication, directly or indirectly, with the BAS 302, the control pumps 102a, 102b and the heat transfer module 220. The smart device 304 can be used for commissioning, setup, maintenance, alert / notifications, communication and control of the control pumps 102a, 102b and the heat transfer module 220. In examples, the smart device 304 can be a smart phone or mobile communication device.

[0168] Figure 3B illustrates a graphical representation of network connectivity of a heat transfer system 320, having remote system setup. The BAS 302 can communicate with the control pumps 102a, 102b and the heat transfer module 220 by a router 306 or via short-range wireless communication. The smart device 304 can access, by way of Internet connection, one or more cloud computer servers over the cloud 308. The smart device 304 can be in communication, directly or indirectly with the BAS 302, the control pumps 102a, 102b and the heat transfer module 230 over the cloud 308. The smart device 304 can be configured for commissioning, setup, maintenance, alert / notifications, communication and control of the control pumps 102a, 102b and the heat transfer module 230. The cloud servers store an active record of measurement of the various equipment, and their serial numbers. When maintenance and service is required, records and notes can be viewed. This can be part of a service application (“app”) for the smart device 304.

[0169] Each heat transfer module 230 can have a HX card 222. A function of the HX card 222 is to connect to all sensors and devices on the heat transfer module 230 either through a physical connection (Controller Area Network (CAN) bus or direct connection) and / or wirelessly. The HX card 222 can also collect information from the pump PC card 226 either through a physical connection or wirelessly.

[0170] The HX card 222 gathers all of the sensor measurement and other information and processes it and controls the flow required to the source side control pump 102b. The HX card 222 also sends sensor readings to the source side control pump 102b and the load side control pump 102a so that they can display real-time information on their respective display screens(s). The HX card 222 can also send the sensor measurement information to the Cloud 308. In an example, all heat exchanger related calculations can be handled by the HX card 222 for more immediate processing. In an example, the other devices can be configured as devices for displaying data previous calculated by the HX card 222.

[0171] The user can modify settings by connecting to the HX card 222 locally using the wireless smart device 304 or the BAS 302. The user can also modify limited settings remotely by connecting to the Cloud 308. These settings will be limited depending on security restrictions.

[0172] When the HX card 222 and the control pumps 102a, 102b are connected through the router 306, then the smart device 304, the PC card 226 and the HX card 222 can communicate using the router 306. When the HX card 222 and the control pumps 102a, 102b are not connected through on the router 306, then the HX card 222 can automatically open a WIFI hotspot for communication between the smart device 304, PC card 226 and HX card 222. When the HX card 222 opens the WIFI hotspot, communication to the Cloud 308 can occur either through the built in loT card, Ethernet connection, SIM card, etc.

[0173] The PC card 226 can connect to the HX card 222 either wirelessly or through a physical connection and provide the HX card 222 with pump sensor data. The PC card 226 can receive data from the HX card 222 (measurement, alerts, calculations) to be displayed on the pump display screen.

[0174] The PC card 226 can communicate to the HX card 222 wirelessly using the ModBUS protocol, as understood in the art. Other protocols can be used in other examples. For communication to occur between the PC card 226 and the HX card 222, the IP addresses of the PC card 226 and the HX card 222 need to be known. Internal identifiers can also be built into the PC card 226 and the HX card 222 such that they can find each other easily on a local area network. The PC card 226 can send information to other devices and accepting information and control from other devices.

[0175] The BAS 302, when used, can connect to the HX card(s) 222 and the PC card(s) 226 wirelessly through the router or through a direct connection. In an example, the BAS 302 has the highest control permissions and can override the HX card(s) 222 and the PC card(s) 226.

[0176] The HX card 222 provides to the Cloud 308 historic measurement data for storage. There can an application on the smart device 304 where the user can view data and generate reports. The Cloud 308 can use historic data to create reports and provide performance management services.

[0177] The smart device 304 can connect locally through the router 306 to the HX card 222 to modify settings. The smart device 304 can also connect to the Cloud 308 where the user can modify a limited number of settings, in an example.

[0178] An application (App), webserver user interface, and / or website can be included so that the user has all the functionality available on the PC card 226 or the Cloud 308.

[0179] The heat transfer system 300, 320 can be configured to provide information to users through the PC card 226, and remotely through online services and a control pump manager. The inputs to the HX card 222 can collect readings and measurements from the two temperature sensors on the cold side fluid and the two temperature sensors on the hot side fluid across the entire heat transfer module 230. Duplex and triplex heat transfer modules 220, 230 can have additional temperature sensors on the outlets of each individual heat exchanger 118a, 118b, 118c to calculate the temperature difference across the single heat exchanger 118a, 118b, 118c. The absolute temperature difference between the two temperature sensors is called the delta T. The HX card 222 and PC card226 can communicate in real time and provide the data to the Cloud 308 for data logging and processing.

[0180] The heat transfer system 300, 320 can operate using demand based controls. Changes in the heat load in the building (load side, in general) will result in changes in flow requirement. In some examples, the control pump(s) 102a on load side will adjust speed to meet the flow requirement in real time based on sensorless (e.g., parallel or coordinated sensorless) operation. In some examples, the control pump 102a calculates the flow in real time and the HX card 222 gets signals from temperature sensors installed on inlet and outlet of heat exchanger(s) 118. The temperature difference is calculated in real time on the HX card 222 and together with flow used to calculate heat load (Q) required in the system load 110a, 110b, 110c, 110d of the building 104 in real time.

[0181] The HX card 222 calculates the optimal flow and temperatures on the source side to achieve the most energy efficient system operation. The source side fluid flow can be controlled by various methods of heat transfer loop control.

[0182] The heat transfer system 300, 320 can monitor the amount of time the system operates at part loads and full loads (duty load) and, when the part load operating time exceeds a set time limit, can operate the control pumps 102a, 102b at full load flow to automatically flush the heat exchanger 118. Operating the pumps at full load flow activates the heat exchanger's 118 self-cleaning ability. This feature is programmed with parameters of cleaning frequency of self-cleaning hours per run time hours and time of day start for self-cleaning. An example default self-cleaning, full load flow operating time is 30 minutes for every 168 hours (7 days) of part load operating time at 3am in the morning. The default part load threshold is set at 90% of full load flow (duty flow).

[0183] In some examples, the user has access to sensor readings on the HX card 222. Connected control pumps 102a, 102b can display real time sensor data on their respective display screens(s). The HX card 222 uploads historic sensor data to the Cloud 308 where the user can access the sensor data.

[0184] In some examples, the HX card 222 can enable heat transfer algorithms (e.g., various heat transfer loop control), real time fouling tracking, and real time error monitoring and maintenance tracking.

[0185] The PC card 226 can communicatively connect to the HX card 222 and display, on the touch screen of the respective control pump 102a, 102b, additional trending, fouling tracking, and maintenance record information. The Cloud 308 can monitor the information and performance reports and error tracking to the customer with current usage, savings, and recommended actions.

[0186] The HX card 222 can store individual heat exchanger data, such as heat transfer module model and serial numbers, design points, mapped heat transfer performance curves (U value as a function of flow). Mapped data of heat transfer curves to be tested in house for each individual heat exchanger 118.

[0187] Service history can be stored on the Cloud 308. Service history can be upload to the HX card 222 through Webserver III, PC card 226, or Cloud 308. If the Cloud 308 does not have the most up to date version then the HX card 222 can push the records to the Cloud 308. If the Cloud 308 has the most up to date version, the Cloud 308 can push the record to the HX card 222.

[0188] For the HX card 222, in some examples, data sampling (inlet and outlet temperatures and pressure of hot and cold side, hot and cold side flow) can be taken every minute up to but not longer than every 5 minutes. Data can be regularly updated and stored on the Cloud 308. All inputs and calculated parameters can be updated as per the sampling time and can be shown on the display screen of the control pump 102a, 102b. The calculated parameters include, delta T, differential pressure, flow, lldirt (overall heat transfer coefficient of heat exchanger after some time of operation), and the heat exchanged (calculated for both the source and load side fluids), total pumping energy, and system efficiency (heat exchanged divided by the total pumping energy, shown in units of Btu / h in imperial and kW in metric).

[0189] Example various controls operations (flow control modes) of the heat transfer system 300, 320 are as follows. 1. Constant speed control. 2. Tsource, out control (Feed Forward Control Mode or Method). 3. Tload, out control (Feed ForwardControl Mode). 4. Proportional Flow Matching. 5. Maximize Source Side Delta T with constant temperature approach and constant load side Delta T. 6. Maximize Source Side Delta T with variable temperature approach and variable load side Delta T. 7. Low Source Delta T Mitigation Method (or feature).

[0190] Some examples of the various control operations (flow control modes) are described in, for example, PCT Application No. PCT / CA2019 / 051428 filed October 4, 2019, the entire contents of which are herein incorporated by reference.

[0191] Figure 4A illustrates a graph 400 of an example heat load profile for a load such as for the load 110a, 110b, 110c, 110d of the building 104 (Figure 1 B), for example, for a projected or measured "design day". The load profile illustrates the operating hours percentage versus the heat load percentage (heat load refers to either heating load or cooling load). For example, as shown, many example systems may require operation at only 0% to 60% load capacity 90% of the time or more. In some examples, a control pump 102a may be selected for best efficiency operation at partial load, for example on or about 50% of peak load. Note that, ASHRAE (RTM) 90.1 standard for energy savings requires control of devices that will result in pump motor demand of no more than 30% of design wattage at 50% of design water flow (e.g. 70% energy savings at 50% of peak load). The heat load can be measured in BTU / hr (or kW). It is understand that the "design day" may not be limited to 24 hours, but can be determined for shorter or long system periods, such as one month, one year, or multiple years.

[0192] Figure 4B illustrates a graphical user interface 410 for configuring the load profile of Figure 4A, in accordance with an example embodiment.

[0193] Figure 4C illustrates a graph 420 of an example flow load profile for the load 110a, 110b, 110c, 110d of the building 104 (Figure 1 B), for a projected or measured “design day”. The load 110a, 110b, 110c, 110d of the building 104 (Figure 1 B) defines pumping energy consumption. Example embodiment relate to optimizing the selection and operation of the heat exchanger 118, the control pump 102a, 102b, and other devices of the building system 100, when the building 104 operates most of the time below 50% flow of duty capacity (100%).

[0194] Figure 4D illustrates a graphical user interface 440 for configuring the load profile 420 of Figure 4C, in accordance with an example embodiment. The load profile 420 includes load data with associated time data (in this example, load percentage with associated time percentage). The graphical user interface screen allows the user to be provided with model numbers of the components of the entire heat transfer system 300, 320, by specified parameters specific to the control pump 102a, 102b and the heat exchanger 118. Features include having the options to select the application (heating, cooling, or both), building type, location, climate location, and zone type which can be used to define a building operating profile. The particular time percentage versus flow percentage can be modelled based on the initial input options, and manually adjusted though the graphical user interface 440 through design or real-time measurement.

[0195] The graphical user interface 440 and generating of the load profiles of the building system 100 can estimate the pump operating energy cost of each specific pump model of the control pump 102a, 102b, selected based on the unique capacity, based on the pump operating hours, building type, geographical location, application and the building’s cost per kWh. This graphical user interface 440 reduces or removes presumptions on any of the equipment and components that have already been imbedded such as what the building’s operating load profile would be what how that reflects in the overall pump operating costs. Previous over all data and models is used for generating the load profiles, for example using data from various and several different pump applications offered globally. In examples, the background data and the graphical user interface 440 can be constantly evolving and updated to ensure the most accurate results are provided.

[0196] The control pumps 102a, 102b can be selected and controlled so that the control pumps 102a, 102b are optimized for partial load rather than 100% load. For example, the control pumps 102a, 102b can have the respective variably controllable motor be controlled along a “control curve” of head versus flow, so that operation has maximized energy efficiency during part load operation (e.g. 50%) of the particular building system 100, such as in the case of the load profile graph 400 (Figure 4A) or load profile graph 420 (Figure 4B). Other example control curves may use different parameters or variables.

[0197] In an example, the controller 116 or another device determines or adjusts the load profile graph 420 based on real-time operation of the building 104 and / or using a testing jig or testing rig.

[0198] Referring again to Figure 1A, the pump device 106a may take on various forms of pumps which have variable speed control. In some example embodiments, the pump device 106a includes at least a sealed casing which houses the pump device 106a, which at least defines an input element for receiving a circulation medium and an output element for outputting the circulation medium. The pump device 106a includes one or more operable elements, including a variable motor which can be variably controlled from the control device 108a to rotate at variable speeds. The pump device 106a also includes an impeller which is operably coupled to the motor and spins based on the speed of the motor, to circulate the circulation medium. The pump device 106a may further include additional suitable operable elements or features, depending on the type of pump device 106a. Some device properties of the pump device 106a, such as the motor speed and power, may be self-detected by an internal sensor of the control device 108a.

[0199] Referring again to Figure 1A, the control device 108a, 108b for each control pump 102a, 102b may include an internal detector or sensor, typically referred to in the art as a “sensorless” control pump because an external sensor is not required. The internal detector may be configured to self-detect, for example, device properties such as the power and speed of the pump device 106a. Other input variables or parameters may be detected. The pump speed of the pump device 106a, 106b may be varied to achieve a pressure and flow setpoint, or a temperature and heat load setpoint, of the pump device 106a in dependence of the internal detector. A program map may be used by the control device 108a, 108b to map a detected power and speed to resultant output properties, such as head output and flow output, or temperature output and heat load output.

[0200] The relationship between parameters may be approximated by particular affinity laws, which may be affected by volume, pressure, and Brake Horsepower (BHP) (hp I kW). For example, for variations in impeller diameter, at constant speed: D1 / D2 = Q1 / Q2; H1 / H2 = D12 / D22; BHP1 / BHP2 = D13 / D23. For example, for variations in speed, with constant impeller diameter: S1 / S2 = Q1 / Q2; H1 / H2 = S12 / S22; BHP1 / BHP2 =S13 / S23. Wherein: D = Impeller Diameter (Ins I mm); H = Pump Head (Ft / m); Q = Pump Capacity (gpm I Ips); S = Speed (rpm I rps); BHP = Brake Horsepower (Shaft Power - hp / kW).

[0201] Variations may be made in example embodiments. Some example embodiments may be applied to any variable speed device, and not limited to variable speed control pumps. For example, some additional embodiments may use different parameters or variables, and may use more than two parameters (e.g. three parameters on a three dimensional map, or N parameters on a N-dimensional map). Some example embodiments may be applied to any devices which are dependent on two or more correlated parameters. Some example embodiments can include variables dependent on parameters or variables such as liquid, temperature, viscosity, suction pressure, site elevation and number of devices or pump operating.

[0202] Figure 5A illustrates a graph 500 of system head versus flow, having operation ranges and selection ranges for one or candidate more heat exchangers 118 for the building system 100. In Figure 5A, there are four candidate heat exchangers HX1 , HX2, HX3, HX4. Figure 5B illustrates a graph 520 of cooling capacity versus flow, having operation ranges and selection ranges for one or more heat exchangers 118 for the building system 100. In Figure 5B, there are two candidate heat exchangers HX3, HX4 that may be in the illustrated range. Figure 5C illustrates a graph 540 of heating capacity versus flow, having operation ranges for one or more candidate heat exchangers 118 for the building system 100. In Figure 5C, there are two heat exchangers HX3, HX4 that may be in the illustrated range.

[0203] In example, the operation ranges also represent selection ranges for a graphical interface for selecting on particular heat exchange 118. For example, in Figure 5A, a user (or a processor) may select on the graph 500 the design point of 35 psi (24.6 m) and 300 US GPM (1136 liters I minute). In such an instance, all of the four heat exchangers HX1 , HX2, HX3 and HX4 may be output by the processor as being a candidate device for installation and operation in the building system 100. If a user selects on the graph 500 the design point of 35 psi (24.6 m) and 1700 US GPM (6435 liters / minute), then only heat exchanger HX4 is output by the processor as being acandidate device for installation and operation in the building system 100. In some examples, the user can then select one of the candidate heat exchangers 118 for installation and operation in the building system 100.

[0204] In an example, a combination of two or more heat exchangers 118 are recommended for installation and operation in the building system 100. The heat exchangers 118 are to be operating in parallel with appropriate selection and control in order to reduce fouling. The heat exchangers 118 may be packaged in a common heat transfer module 220, 230. In other examples, the heat exchangers 118 are separate heat exchangers 118 which are installed in parallel. The smaller sized individual heat exchangers 118 are each smaller than a single large heat exchanger 118 to fulfill system load.

[0205] Similarly, when the known design point of the building system 100 is cooling capacity, then the graph 520 of Figure 5B can be used to select the candidate heat exchanger 118 (or plurality of heat exchangers 118 for installation in parallel). When the known design point of the building system 100 is heating capacity, then the graph 540 of Figure 5C can be used to select the candidate heat exchanger(s) 118.

[0206] In some examples, once one or more candidate control pumps 102a, 102b and heat exchangers 118 are determined by the processor, the total cost of selecting, installing and operating the heat exchangers 118 and other components of the building system 100 can be optimized using at least one processor or the controllers 116.

[0207] Figure 7A illustrates a flow diagram of an example method 700 for automatic maintenance on a heat exchanger 118, in accordance with an example embodiment. The method 700 is performed by the controllers 116 (which may include processing performed by the HX card 222 in an example). At step 702, the controllers 116 operate the control pumps 102a, 102b across the heat exchanger 118 in accordance with the system load 110a, 110b, 110c, 110d. Step 702 also includes activating a number of heat exchangers 118 according to the system load 110a, 110b, 110c, 110d, for example by opening or closing a respective valve 224 (or maintaining a state of the valve 224). At step 704, the controllers 116 determine that maintenance (i.e. flushing) is required on the heat exchanger 118 based on real-time operation measurement whensourcing the system load 110a, 110b, 110c, 110d. At step 706, the controllers 116 perform automatic maintenance (flushing) on the heat exchanger 118 by controlling flow to a maximum flow. In various examples, maximum flow be can controlling of the control pumps 102a, 102b to their respective maximum flow capacity, or a maximum flow that is supported by the load 110a, 110b, 110c, 110d (i.e. , duty load), or a maximum flow capacity of the heat exchanger 118. The maximum flow is used to flush the fouling in the heat exchanger 118. In example embodiments, step 706 can be performed during realtime sourcing of the system load 110a, 110b, 110c, 110d, with appropriate compensation to account for the increase in flow. At step 708, the controllers 116 determine whether the flushing from step 706 was successful, and if so the method 700 returns to step 702. If not, the controllers 116 alert another device such as the BAS 302 or the smart device 304 that manual inspection, repair or replacement of the heat exchanger 118 is required.

[0208] Regarding step 702, the control of the control pumps 102a, 102b and the number of the heat exchangers 118 can be performed by the controllers 116 to optimize at least parameter one of the heat exchangers 118 that are open.

[0209] In an example, the control pumps 102a, 102b are operated in a so-called sensorless manner. The controllers 116 optimize at least one parameter of the heat exchangers 118 that are open with knowledge of how the control pumps 102a, 102b control themselves.

[0210] Another example of the automatic maintenance and flushing of the heat exchanger 118 is to control one or both of the control pumps 102a, 102b to and from the maximum flow, for example between maximum flow and another specified flow level. In another example, this control between two flow levels is a sinusoidal function.

[0211] Another example of the automatic maintenance and flushing of the heat exchanger 118 is to control one or both of the control pumps 102a, 102b to provide pulsing of flows. In an example, the controllers 116 sets the flow of the control pumps 102a, 102b to a specified flow level, and then controls the control pumps 102a, 102b to have short bursts of increased flow, reverting back to that specified flow level. In some examples, the present desired flow that is already being used to source the system load 110a, 110b, 110c, 110d (for building 104) is controlled to have short bursts of increasedflow, with shortly reverting back to the present desired flow. This type of maintenance is less disruptive and can be performed during normal operation of the building 104 and the sourcing of the system load 110a, 110b, 110c, 110d. An example of the burst is a specified increase from the specified flow level to an increased flow level for a specified period of time, followed by reversion to the specified flow level for a second specified period of time, and repeating for a third specified period of time or until successful flushing is detected.

[0212] If it is determined that the pulsing of flows was not effective for flushing of the heat exchanger 118, then in some examples, the controllers 116 can subsequently perform the automatic maintenance using maximum flow of one or both of the control pumps 102a, 102b through the heat exchanger 118. Effectiveness or success (versus non-effectiveness or non-success) can be determined by way of a variable (or parameter) of the heat exchanger 118 exceeding a threshold, examples of the variable being the heat transfer coefficient (U) of the heat exchanger 118, delta pressure across the heat exchanger 118, or the heat transfer capacity of the heat exchanger 118.

[0213] Step 704 will now be described in greater detail. Different alternative example embodiments of step 704 are outlined in Figures 7B, 7C, and 7D. In step 704-1 Figure 7B, the controllers 116 compare real-time operation measurement of the heat exchanger 118 with the new clean heat exchanger 118 as a baseline. At step 722, the controllers 116 determine a baseline heat transfer coefficient (U) of the new clean heat exchanger 118. Step 722 can be done using a testing rig, or can be performed using runtime setup and commissioning when installed in the building system 100, or both. At step 724, the controllers 116 determine, during real-time operation of the control pumps 102a, 102b in order to source the system load 110a, 110b, 110c, 110d, the real-time heat transfer coefficient (U) of the heat exchanger 118. At step 726, the controllers 116 perform a comparison calculation between the real-time heat transfer coefficient (U) of the heat exchanger 118 and the baseline. In an example, the comparison calculation is a Fouling Factor calculation. At step 728, the controllers 116 determine whether the calculation satisfies criteria, and if so then at step 730 the controllers 116 conclude that the control pumps 102a, 102b are to perform automatic maintenance on the heatexchanger 118. If not, the controllers 116 loop operation back to step 724, which is determining of the real-time heat transfer coefficient (U) of the heat exchanger 118.

[0214] Figure 7C illustrates a flow diagram of an alternate example of step 704-2, for determining that the control pumps 102a, 102b are to perform maintenance on the heat exchanger 118. In this example, the controllers 116 compare real-time operation measurement of the heat exchanger 118 with the just-cleaned heat exchanger 118 as a baseline. At step 740, maintenance (flushing) has been completed on the heat exchanger 118. In other examples, at step 740 the system has completed operating at full load (full flow) for a specified period of time, which has a similar effect. At step 742, the controllers 116 determine a baseline heat transfer coefficient (U) of the just-cleaned heat exchanger 118. Step 742 can be done while still sourcing the load 110a, 110b, 110c, 110d of the building system 100. At step 744, the controller 116 determine, during real-time operation of the control pumps 102a, 102b to source the system load 110a, 110b, 110c, 110d, the real-time heat transfer coefficient (U) of the heat exchanger 118. At step 746, the controllers 116 perform a comparison calculation between the real-time heat transfer coefficient (U) of the heat exchanger 118 and the baseline. At step 748, the controllers 116 determine whether the calculation satisfies criteria, and if so then at step 750 the controllers 116 conclude that the control pumps 102a, 102b are to perform automatic maintenance on the heat exchanger 118. If not, the controllers 116 loop operation back to step 744, which is determining of the real-time heat transfer coefficient (U) of the heat exchanger 118.

[0215] Figure 7D illustrates a flow diagram of another alternate example of step 704-3, for determining that the control pumps 102a, 102b are to perform maintenance on the heat exchanger 118. In this example, the controllers 116 determine that the heat exchanger 118 has been operating continuously at part load for a specified period of time, and therefore requires flushing. At step 760, the controllers 116 reset a timer. At step 762, the controllers 116 determine whether the heat exchanger 118 has been operating continuously at part load, which can be any part load or can be a specified maximum such as at most 90% full load. If so, at event 764 the timer is started. If not, the controllers 116 loop back to step 760. At step 766, the controllers 116 determine whether the part load has occurred continuously for a specified period of time, for example at least7 days. If so, at step 768 the controllers 116 conclude that the control pumps 102a, 102b are to perform automatic maintenance on the heat exchanger 118. If not, this means that the load 110a, 110b, 110c, 110d is operating at full load (full flow) anyway and therefore the controllers 116 loop back to step 760 and the timer is reset again.

[0216] In another alternative example embodiment of step 704 (Figure 7A), the controllers 116 are configured to determine that the heat exchanger 118 requires maintenance due to fouling of the heat exchanger 118 by: predicting, from previous measurement of the flow, pressure and / or temperatures sensors during the real-time operation measurement when sourcing the variable load, an actual present heat transfer coefficient (U) of the heat exchanger 118; and calculating a comparison between the predicted actual coefficient value of the heat exchanger 118 and the clean coefficient value of the heat exchanger 118. The predicting can be performed based on: previous actual measurement results; first principals from physical properties of the devices; testing data from a testing rig, sensor data from previous actual operation, or other previous stored data from the actual device or devices having the same or different physical properties; and / or machine learning. Example parameters of the heat exchanger 118 that can be predicted include: flow capacity, fouling factor (FF or Rf), heat transfer capacity (Qc) and heat transfer coefficient (U). The prediction can be based using a polynomial fit over time to extrapolate future performance and parameters of the heat exchanger from past readings and calculations.

[0217] Performance parameter services can be provided by the controllers 116. An example trending data (or coefficient) provided by performance management service is the heat transfer capacity (Qc) or heat transfer coefficient (U value) of the heat exchanger 118, as well as the future heat transfer capacity or heat transfer coefficient of the heat exchanger 118, based on trendline analysis over time, historical data from the same or similar pumps 102a, 102b, or mathematical calculations. The remaining time of life of the heat transfer capacity or heat transfer coefficient of each the heat exchanger 118 (that would result without intervention such as automatic or manual maintenance) can also be determined by the controllers 116. Similar trend data (over time, and projected for the future) can be provided in relation to the fouling factor (FF) and the heat transfer coefficient (U).

[0218] An example calculation of heat transfer efficiency (E) of a heat exchanger 118 can be calculated as: E = Qc / Qmax, wherein Qc is an actual heat transfer capacity (or rate) and Qmax is a (theoretical) maximum possible heat transfer capacity (or rate).

[0219] Referring again to Figure 7A, step 706 (performing automatic maintenance on the heat exchanger 118) will now be described in greater detail. Step 706 is typically performed during real-time sourcing of the load 110a, 110b, 110c, 110d. Step 706 can be performed without disassembling or providing bypass loops to the heat exchanger 118. In one example, both pumps 102a, 102b operate at full duty flow (or full permissible load) simultaneously for 30 minutes. In another example, both pumps 102a, 102b operate at full duty flow (or full permissible load) in sequence, one at a time (e.g., 30 minutes each). In other example embodiments, rather than full flow, the pumps 102a, 102b can be controlled to be at a sequence of specified flows, such as alternating between 90% flow and full flow, to assist in dislodging the fouling. In other example embodiments, the pumps 102a, 102b can be controlled to provide backflow to the heat exchanger 118, e.g. when the load 110a, 110b, 110c, 110d is a 2-way load. The backflow may be performed on its own or as part of the sequence of specified flows.

[0220] In another example, the maintenance to the heat exchanger 118 is only applied to one fluid path. For example, when there is sourcing from the cooling towers 124 (Figure 1A) or hot, dirty geothermal water (Figure 1 J), the automatic maintenance may be performed by only one pump 102b on the source side to flush the source fluid path only, which can contain an abundance of fouling.

[0221] In another example, step 706 can be delayed until a suitable off-hours time, such as the weekend or after business hours, where variable changes in flow for the maintenance will be less noticeable and the instantaneous load 110a, 110b, 110c, 110d is more predictable.

[0222] Referring again to Figure 7A, step 708 (determining whether flushing was successful) will now be described in greater detail. Step 708 can be the same calculation as step 724 or step 744. Step 708 can be calculating or determining, during real-time operation of the control pumps 102a, 102b to source the system load 110a, 110b, 110c, 110d, the real-time heat transfer coefficient (U) of the heat exchanger 118 as the newbaseline coefficient (U). Therefore, immediately after the flushing was performed at step 706, the controllers 116 calculate the present heat transfer coefficient (U) of the heat exchanger 118 and compares with the baseline coefficient (U). If a calculation between the present heat transfer coefficient (U) and the baseline coefficient (U) (e.g., fouling factor, percentage difference, ratio, etc.) exceeds a threshold difference, then flushing was not successful and the alert is sent at step 710. In some examples, not shown, reflushing (as in step 706) may be performed again for one or two more times when the flushing was found not to be successful. If the calculation is within a threshold difference, then flushing was successful and at step 702 the heat exchanger 118 and pumps 102a, 102b operate as normal to source the load 110a, 110b, 110c, 110d. Based on the calculation, controllers 116 can output a notification to a display screen or another device in relation to the flushing of the fouling of the heat exchanger being successful or unsuccessful.

[0223] The method 700 of Figure 7A can be applied to: a heat transfer module having a single heat exchanger 118; the heat transfer module 220 having two heat exchangers 118a, 118b (Figure 2B); and the heat transfer module 230 having three heat exchangers 118a, 118b, 118c (Figure 2C), or a heat transfer module having more than three heat exchangers 118. In an example, the method 700 can use a parameter such as the heat transfer coefficient (U) of the entire heat transfer module 220, 230, rather than individual heat exchangers 118, in some examples. The method 700 can use a parameter such as the heat transfer coefficient (U) of the individual heat exchangers 118a, 118b, 118c in other examples. By monitoring individual heat exchangers 118a, 118b, 118c, the controllers 116 can determine that only one of the individual heat exchangers 118a, 118b, 118c in the heat transfer module 230 requires automatic maintenance (flushing). It can also be determined by the controllers 116 whether only one individual heat exchanger 118a, 118b, 118c in the heat transfer module 230 requires manual repair, replacement, maintenance, chemical flushing, etc.

[0224] For example, when performing step 706 (performing automatic maintenance on the heat exchanger 118), the flushing can be performed on individual heat exchangers 118a, 118b, 118c, for example by the controllers 116 (or HX card 222) opening or closing the applicable valves 224. In one example, less than all of theindividual heat exchangers 118a, 118b, 118c may have fouling and only that heat exchanger 118a, 118b, 118c requires flushing. In other example, when the entire heat transfer module 230 requires flushing, each individual heat exchanger 118a, 118b, 118c may be flushed one at a time (or less than all at a time). By having less than all of the individual heat exchangers 118a, 118b, 118c being open, this partial operation of the heat transfer module 230 can offset the increased flow of the pumps 102a, 102b to full flow when sourcing the variable load in real-time (which is often at partial load and doesn’t require full flow).

[0225] Figure 8A illustrates a graph 800 of simulation results of brake horsepower versus time of a control pump 102a, 102b operating through various heat exchangers having various foul factors. The y-axis is brake horsepower in horsepower (alternatively Watts). The x-axis is time. Plot line 802 is the clean, ideal brake horsepower, and remains horizontal over time as shown in the graph 800. Plot line 804 is the brake horsepower of the heat exchanger 118 having automatic maintenance in accordance with example embodiments. Plot line 804 illustrates that the Fouling Factor (FF or Rf) after the period of time is 0.0001. Additional plot lines are shown for the scenario when there is no automatic maintenance. Plot lines 806, 808, 810 illustrate higher Fouling Factors of the heat exchanger and higher brake horsepower of the control pump 102a, 102b that result when operating at higher required pressures (in PSI, alternatively in Pa) and flow (in Gallons Per Minute (GPM), alternatively liters / m inute), when there is no automatic maintenance. Circle 812 is a detail view of the graph 800, which illustrates in plot line 804 that vertexes 814 occur when there is automatic flushing, and therefore the required brake horsepower is reduced after each flushing.

[0226] In an example, the plot lines on the graph 800 are plotted based on actual measurement results from one or more of the sensors. In some examples, using any or all of: the actual measurement results; first principals from physical properties of the devices; testing data from a testing rig, sensor data from actual operation, or other previous stored data from the actual heat exchanger or heat exchangers having the same physical properties or different physical properties; and / or machine learning, the plot lines can be predicted by the controllers 116 for determining the future parameters over time (or at a specific future time) of the heat exchanger. The parameters can include, e.g. flowcapacity, fouling factor (FF), heat transfer capacity (Qc) and heat transfer coefficient (U). In an example, the plot lines can be determined and represented using a function such as a polynomial equation, e.g. quadratic or a higher order polynomial.

[0227] For example, the controllers 116 can be configured to calculate and predict the parameters of the heat exchanger, such as present flow capacity, fouling factor (FF), heat transfer capacity (Qc) and heat transfer coefficient (U). Given the rate or amount of fouling, the controllers 116 can be configured to calculate and predict the future parameters of the heat exchanger. The controllers 116 can be configured to calculate and predict the parameters of the heat exchanger to further account for accumulated fouling, instances of flushing (manual, or automated as described herein), instances of chemical washing, etc. For example, plot line 804 illustrates that there is still a small amount fouling that occurs, even with the automated flushing. Historical information and historical performance response of the heat exchanger, or other heat exchangers, can be used for the predicting. In some examples, the controllers 116 can compare actual sensor information and calculations of the heat exchanger with the predicted parameters to provide data training sets for future predictions by the controllers 116.

[0228] In some examples, the controllers 116 can be configured to predict and recommend, based on trend line or other analysis, when (the day) the maintenance of the heat exchanger 118 will require maintenance. The prediction and recommendation can be based on a user input defined percentage of useful heat transfer capacity or heat transfer coefficient remaining, or based on a specified percentage of heat transfer capacity or heat transfer coefficient remaining, or based on other predictive calculations.

[0229] Figure 6A illustrates a graph 600 of heat transfer coefficient value (U-Value) versus flow of a clean heat exchanger 118. In an example, testing was performed prior to shipping and / or prior to installation of the heat exchanger 118. The solid line 602 represents the measured U-Values. The dotted line 604 represents a polynomial fit of the measured U-Values. The coefficients of the solid line 602 can be stored in memory in an example, and can be compared directly with real-time measurements (at the same or interpolated flows). The polynomial fit for the dotted line 604 is a quadratic in this example, and can be also be higher order polynomials, depending on the amount of fitrequired, or other equations or models. Another example variable or parameter that can be tested and determined is the heat transfer capacity of the clean heat exchanger 118, and subsequent determination of the heat transfer capacity of the heat exchanger 118 when in use.

[0230] To determine the measured U-Values for the solid line 602, performance mapping is performed at duty conditions and one alternate condition with different temperatures, using a testing rig. The source flow (Fsource) and load flow (Fload) are varied proportionally to operate at 100%, 90%, 80%, 70%, 60%, 50%, 40%, and 30% of full duty flow, in order to determine the U-values.

[0231] Performance is mapped for each heat exchanger 118 and the data is stored on the HX card 222 and the cloud 308, and the stored data linked to the unique serial number of the heat exchanger 118a, 118b, 118c. At the time when the heat exchanger 118a, 118b, 118c is installed or assembled onto the heat transfer module 230, the performance map for each heat exchanger 118a, 118b, 118c is uploaded to the cloud server and stored onto the HX card 222. This testing to be completed on a testing rig at the factory, prior to shipping and / or installation of the heat transfer module 230. In other examples, the testing rig is performed at a third party testing facility. Required capacities for the testing rig can to be up to 600gpm (or in liters / min) and up to 15,000,000 Btu / hr (or in kW) at a 20F (or equivalent in differential K) liquid temperature difference.

[0232] The clean U-values can then be compared with the real-time calculated U-values determined during real-time sourcing of loads 110a, 110b, 110c, 110d using the heat exchanger 118 and the control pumps 102a, 102b, at the various flow rates. The polynomial fit, first principals based on physical properties of the heat exchanger, and / or predictive future performance can be used for determining expected U-values of the heat exchanger during real-time operation and sourcing of the variable load. Interpolation can also be performed between specifically tested flow values.

[0233] In some examples, the controllers 116 can be configured to predict and recommend, based on trend line or other analysis, what is the heat transfer capacity or heat transfer coefficient of the clean heat exchanger 118 after the automated maintenance is performed.

[0234] The heat transfer coefficient U of the clean heat exchanger 118 can be calculated as follows:llclean = Qavg / (Ax LMTD)

[0235] Where Qavg is the average of the measured heat transfer across the load fluid path and the source fluid path, as follows:Qavg = (Qload + Qsource) / 2

[0236] Qload can be calculated from measurements of flow sensors and temperature sensors, as follows (similar calculation for Qsource):Qload = C x m x abs(Tin - Tout)= Cload x pload x Fload, measured x abs(Tload, out, measured - Tload, in, measured),where:C, is the is the specific heat capacity as a function of pressure and temperature, m is the mass flow rate,Fload is Flow of the load,pload is the fluid density at the average of Tload, out, measured - Tload, in, measured,Cload is the specific heat capacity of the load side fluid at the average of Tload, out, measured - Tload, in, measured.

[0237] The heat transfer capacity (Qc) is the amount of heat energy that can be transferred across the heat exchanger 118 under design conditions. As the heat transfer coefficient (U) degrades the heat transfer capacity Qc also degrades. In a system design there is a required minimum threshold of acceptable heat transfer capacity Qm. When the Qc becomes less than Qm, then cleaning, automated maintenance (e.g. flushing), manual service, or replacement may be performed, and / or an alert for same can be output.

[0238] In some examples, the heat transfer coefficient llclean or the heat transfer capacity (Qc) can be determined using a testing rig that simulates the flow and temperature conditions. In some examples, the heat transfer coefficient llclean or the heat transfer capacity (Qc) can also be determined and calculated using real-time operation when the heat exchanger 118 is initially installed to service the system load 110a, 110b, 110c, 110d.

[0239] The operating point(s) at duty conditions can be tested and then stored to the HX card 222. Such operating points include Fsource, design, Tsource, in, design, Tsource, out, design, Fload, design, Tload, out, design and Tload, in, design, Qload, design, FluidTypesource, FluidTypeload, Psource, design, and Pload, design. There is a provision to store multiple sets of duty conditions on the HX card 222 and can be editable.

[0240] Referring still to Figure 6A, rather than by testing, in other examples the graph 600 can be determined by first principle calculations, e.g. based on known dimensions of the heat exchanger 118 (and the brazed plates 202) and the fluid properties of the circulation mediums.

[0241] Referring to step 724 (Figure 7B) and step 744 (Figure 7C), calculating the heat transfer coefficient (U) of the heat exchanger 118 when sourcing the system load 110a, 110b, 110c, 110d in real-time will now be described in greater detail. A similar process can be performed when determining the clean heat transfer coefficient (U) of the heat exchanger 118. Another example variable or coefficient of the heat exchanger 118 that can be determined and analyzed in accordance with example embodiments is heat transfer capacity.

[0242] The amount of fouling in the heat exchanger 118 can be output to a screen or transmitted to another device for showing heat transfer performance. The performance can be indicated by color coding, where Green is indicative of a clean exchanger, Yellow is indicative of some fouling, and Red as maintenance and cleaning required. In an example, the processing of this heat exchanger fouling is completed by the HX card 222 and sent to the Cloud 308, for output to the screen of the smart device 304, or sent to theBAS 302. Units of displayed data can be available in both imperial (F, ft, gpm, BTU / h) and metric units (C, m, l / s, kW).

[0243] The heat exchanged can be calculated for fluids that comprise of water and ethylene I propylene glycol mixtures up to 60%. Thermodynamic data for these fluids are available on the HX card 222, with 5% minimum increments for glycol mixtures.

[0244] The heat transfer calculations are follows.Q = m x C x (Tin - Tout),where,Q, is the heat transferred,C, is the is the specific heat capacity as a function of pressure and temperature,m, is the mass flow rate,Tin is the inlet temperature of the fluid stream,Tout is the outlet temperature of the fluid stream.

[0245] For a heat exchanger:QHX = U x A x (LMTD),where,QHX, is the heat transferred through the heat exchanger,U is the overall heat transfer coefficient for the specific heat exchanger, A, is the heat transfer surface area (generally constant).

[0246] LMTD (counter flow configuration) is the log-mean temperature difference defined by (sometimes source side is referred to as hot side and load side is referred to as cold side):LMTD = [(Tsource, in - Tload,out) - (Tsource,out - Tload, in)] I ln[(Tsource, in - Tload, out) I (Tsource, out - Tload, in)],where,Tsource, in is the inlet (to heat exchanger) fluid temperature on source side, Tsource, out is the outlet (from heat exchanger) fluid temperature on source side,Tload, in is the inlet (to heat exchanger) fluid temperature on load side, Tload, out is the outlet (from heat exchanger) fluid temperature on load side.

[0247] llclean is the overall heat transfer coefficient with a clean, ideal heat exchanger, Udirt is the overall heat transfer coefficient at a specific time during operation. The U-values (under clean conditions) can be adjusted during factory testing and mapped into the HX card 222. The llclean (Fsource, Fload, Tsource, in, Tsource, out, Tload, in, Tload, out) is a function specific to selection and geometry for each heat exchanger, as a mathematical formula, and can be verified during factory testing and mapped on to the HX card 222.

[0248] In order to determine the current U value, lldirt:Udirt = Qavg / (A x LMTD)

[0249] Where Qavg is the average of the measured heat transfer across the load fluid path and the source fluid path, as follows:Qavg = (Qload + Qsource) / 2

[0250] Calculations for Qload and Qsource have been provided in equations herein above.

[0251] If Udirt is smaller than Uclean by more than 20% (or other suitable threshold), then a warning is output by the HX card 222, for example to the BAS 302, the cloud 308 and the smart device 304.

[0252] In some examples, Uclean and Udirt should be only compared for a certain range of flows from 100% to 50% of duty point.

[0253] One example comparison calculating for the heat transfer coefficient is a fouling factor (FF or Rf):FF = 1 / Udirt- 1 / Uclean

[0254] A lower FF is desired. In an example, when the FF is at least 0.00025, then it is concluded that maintenance (flushing) should be performed on the heat exchanger 118. A FF of 0.0001 can be deemed to be acceptable, and no maintenance is required. A baseline FF can also be calculated for the clean heat exchanger 118.

[0255] Referring to step 724 (Figure 7B) and step 744 (Figure 7C), as an alternative to calculating the heat transfer coefficient (U), it can be appreciated that other parameters or coefficients can be calculated by the controllers 116 to determine whether maintenance is required on the heat exchanger 118 due to fouling, and that flushing maintenance is required.

[0256] In an example, heat load (Q) or the related heat transfer capacity (Qc) can be used to determine that maintenance is required. Flow measurement can be received from a first flow sensor of the source fluid path, and a second flow sensor of the load fluid path. The flow measurement information from the flow sensors is used for said determining that the heat exchanger 118 requires maintenance due to fouling of the heat exchanger 118. A heat load (Q) can be calculated for each fluid path based on the respective flow and the temperatures. First, a clean heat load (Q) for each of the source fluid path and the load fluid path of the heat exchanger 118 when in a clean state can be determined for a baseline. During real-time sourcing of the load 110a, 110b, 110c, 110d, real-time flow and temperature measurement can be determined from each of the source fluid path and the load fluid path of the heat exchanger 118. A real-time heat load (Q) can be calculated from the real-time measurements. Calculating a comparison between the baseline and the actual heat load (Q) can be used to determine that maintenance is required, when the comparison calculation exceeds a threshold difference.

[0257] If Qsource varies more than Qload by more than 10%, for example, then a warning is given to the user. In other words, if:Abs(Qsource - Qload) / max(Qsource - Qload) > 0.10

[0258] The variation can be taken from the running average of 100 consecutive readings. Any spikes can be filtered to avoid erratic controls. A difference of more than 3 standard deviations can be excluded.

[0259] In an example, pressure measurement can be used to determine that maintenance is required. A first differential pressure sensor is used to detect differential pressure across the source fluid path. A second differential pressure sensor is used to detect differential pressure across the load fluid path. A clean pressure differential value across each of the fluid paths of the heat exchanger 118 is determined when the heat exchanger 118 is in a clean state, as a baseline. When sourcing the load 110a, 110b, 110c, 110d, real-time measurement of the pressure differential is determined by the controllers 116 and a comparison is calculated between the real-time measurement and the baseline. If the comparison calculation exceeds a threshold difference, then maintenance is required.

[0260] For example, if the differential pressure is 20% higher than that of the pressure drop curve across the clean heat exchanger, then a warning is given to indicate some fouling (Yellow). If the differential pressure is 30% higher than that of the pressure drop curve across the clean heat exchanger, then a warning is given to indicate fouling (Red).

[0261] In an example, temperature measurement can be used to determine that maintenance of the heat exchanger 118 is required. A clean temperature differential value across each of the source fluid path and the second fluid path of the heat exchanger 118 when in a clean state is determined as a baseline. The controllers 116 can determine real-time temperature measurements, and calculate a comparison between the actual temperature differential value of the heat exchanger 118 and the baseline temperature differential value of the heat exchanger 118. If the comparison calculation exceeds a threshold difference, then maintenance is required.

[0262] When there is more than one heat exchanger 118a, 118b, 118c within the heat transfer module 230, the temperature sensors on each heat exchanger 118a, 118b, 118c is used to monitor individual heat exchanger fouling. The temperature of the inlet and outlet fluid streams are measured for every heat exchanger. If the fluid streamtemperature difference on a specific heat exchanger differs by more than 1 F (or equivalent in K) than the average of fluid steam temperature difference for all heat exchangers, then a warning given to indicate that the specific heat exchanger 118a, 118b, 118c is fouled and needs to be checked or have automatic flushing performed thereon. In an example, this scenario must be present for more than 1000 consecutive readings before a warning is sent.

[0263] Figure 6B illustrates an example graph 620 of heat transfer coefficient value (U-Value) versus flow of a heat exchanger 118. Low fluid velocities can lead to mal distribution of flow in the heat exchanger or laminar flow, and thus leading to lowered heat transfer efficiency overall and over time. Illustrated is the OEM claim points and a correlation fit curve (e.g. polynomial or otherwise). A plurality of such heat exchangers 118 may be collectively in a heat transfer module 220, 230, or as individual heat exchangers 118 installed in parallel. In examples, the heat exchangers 118 can be the same size or model, or can be of different size or model.

[0264] In an example embodiment, the heat exchangers 118 are controlled by the controller 116 to operate in a staged manner, so as to operate at a higher heat transfer coefficient value (U-value). For example, a plurality of heat exchangers 118 are controlled to be activated (opened) one at a time, or deactivated (closed) one at a time. For example, the first heat exchanger 118a is activated at a startup flow condition. When the flow causes a first threshold value (e.g. U-value or flow value), the second heat exchanger 118b is activated by the controller 116. When the flow causes a second threshold value (e.g. flow value, or an individual or collective U-value), the third heat exchanger 118c is activated by the controller 116. The same method can be performed to deactivate (close) the heat exchangers 118 in a staged manner when flow decreases. In an example, the flow value is a flow velocity.

[0265] Figure 8B illustrates a graph 820 of fouling factor versus flow velocity for specific types of impurities. The illustrated impurities include biological, crystallization, particulate, and corrosion. After an initial peak (as impurities are limited for very low water flow velocity), the amount of fouling generally reduces as water flow velocity increases.

[0266] Example of operating values and threshold values can be seen in the operation ranges in Figures 5A, 5B and 5C. For example, instead of a single heat exchanger, a first heat exchanger 118a can be designed to be smaller than the single heat exchanger and having a threshold value, in which a next second heat exchanger 118b is activated when the threshold value of the first heat exchanger 119a is reached (can be within a buffer). Examples of the threshold value include U-value, heat transfer capacity (Qc), flow value (e.g. Ipm, or flow velocity in meters per second). Other examples of the threshold value can include system head (Figure 5A), cooling capacity (Figure 5B) or heating capacity (Figure 5C). In an example, the controller 116 can map detected values to coefficient values of the heat exchangers 118, and determining when threshold values are reached, for activating or deactivating the relevant number heat exchangers 118, as applicable.

[0267] Reference is again made to step 702 of Figure 7A, the control of the number of the heat exchangers 118 can be performed by the controllers 116 to optimize at least parameter one of the heat exchangers 118 that are open. In some examples, the controller 116 directly maps system flow values to the number of heat exchangers 118 that are controlled to be operating, and accordingly activates (or deactivates) the required number of heat exchangers 118 to satisfy the system flow while optimizing or having a suitably high turbulent flow through the heat exchangers 118.

[0268] In examples, a particular stage sequence may be skipped (e.g. due to a very large increase or decrease in flow requirement), for example transitioning directly from activating the first heat exchanger 118a to activating three or more of the heat exchangers 118 (i.e. by at least two more of the heat exchangers 118). Similarly, the number of heat exchangers 118 that are activated can be decreased by at least two of the heat exchangers 118, by closing the relevant heat exchangers 118. For example, when there are three open heat exchangers 118, two of the heat exchangers 118 would be closed.

[0269] In an example, the valves 224 of the heat exchangers 118a, 118b, 118c are variably controllable valves as another aspect of the control by the controller 116. The flow through the heat exchangers 118a, 118b, 118c are variable controlled across aspectrum of flow rates in order to have the heat exchanger 118 operate at a higher flow value or flow speed value, so as to operate above the requisite threshold coefficient value (e.g. U-value or Qc value).

[0270] An example embodiment is the controller 116 is configured to stage multiple heat exchangers 118 to optimize one or more parameters.

[0271] An example embodiment is the controller 116 is configured to stage multiple heat exchangers 118 to optimize heat transfer efficiency over time.

[0272] An example embodiment is the controller 116 is configured to stage multiple heat exchangers 118 to optimize heat transfer efficiency over time accounting for fouling.

[0273] An example embodiment is the controller 116 is configured to automatically clean the heat exchanger 118 by increasing flow velocity in individual heat exchangers 118 over time.

[0274] An example embodiment is a heat transfer system 300, 320, comprising: a plurality of heat exchangers 118 in parallel configured for connection to a first fluid circuit and a second fluid circuit; a respective valve 224 for each of the heat exchangers 118; and at least one controller configured to: control the respective valve 224 to optimize at least one parameter of each of the heat exchangers 118.

[0275] In another example embodiment of any of the above, the at least one parameter of each of the heat exchangers 118 includes: heat transfer efficiency; heat transfer coefficient (U); heat transfer capacity (Qc); flow value up to flow capacity; flow velocity value; pressure drop value; temperature load capacity, and / or fouling factor.

[0276] In another example embodiment of any of the above, the at least one parameter of each of the heat exchangers 118 includes a coefficient value of each of the heat exchangers 118.

[0277] In another example embodiment of any of the above, the at least one parameter includes cost over part load operation, wherein the cost is based on operating cost and replacement cost.

[0278] In another example embodiment of any of the above, the controlling the respective valve 224 is in a staged manner.

[0279] In another example embodiment of any of the above, the controlling the respective valve 224 in the staged manner includes maximizing flow velocity for each of the plurality of heat exchangers 118 having the respective valve 224 that is open.

[0280] In another example embodiment of any of the above, the optimizing the at least one parameter includes optimizing the at least one parameter over time.

[0281] In another example embodiment of any of the above, the optimizing the at least one parameter over time is over a time of life of each of the heat exchangers 118.

[0282] In another example embodiment of any of the above, the respective valve 224 is a respective variable control valve 224.

[0283] In another example embodiment of any of the above, the optimizing includes controlling at least one of the respective valve 224 to a partially open state.

[0284] In another example embodiment of any of the above, the respective valve 224 is a respective shutoff valve.

[0285] In another example embodiment of any of the above, the controlling the respective valve 224 is performed during real time sourcing of a variable load.

[0286] In another example embodiment of any of the above, the controlling the respective valve 224 includes opening only an individual one of the heat exchangers 118 to flush a fouling of the individual one of the heat exchangers 118 during real time sourcing of a variable load.

[0287] In another example embodiment of any of the above, the heat transfer further includes: first at least one variable control pump for providing variable flow of a first circulation medium through the first fluid circuit; and at least one flow control mechanical device for providing variable flow of a second circulation medium through the second fluid circuit, wherein the at least one controller is configured to control the first at least one variable control pump and the flow control mechanical device to perform the optimizing during real time sourcing of a variable load.

[0288] In another example embodiment of any of the above, the controlling the first at least one variable control pump is to a first flow amount during the real time sourcing of the variable load in order to flush a fouling of each of the plurality of heat exchangers 118 having the respective valve 224 that is open.

[0289] In another example embodiment of any of the above, the at least one flow control mechanical device includes second at least one variable control pump or a variable control valve 224.

[0290] In another example embodiment of any of the above, the at least one parameter of each of the heat exchangers 118 includes an affect of that heat exchanger 118 on operating cost of or pressure drop fulfillment by the first at least one variable control pump.

[0291] In another example embodiment of any of the above, the controlling the respective valve 224 includes opening less than all of the valves 224 at a time.

[0292] In another example embodiment of any of the above, the at least one controller is located remote to the plurality of heat exchangers 118.

[0293] In another example embodiment of any of the above, the plurality of heat exchangers 118 are integrated in a heat transfer module 220, 230 which is configured to be connected to the first fluid circuit and the second fluid circuit.

[0294] In another example embodiment of any of the above, the at least one controller is integrated with the heat transfer module 220, 230.

[0295] In another example embodiment of any of the above, the at least one controller is separate from the heat transfer module 220, 230.

[0296] In another example embodiment of any of the above, the heat transfer system 300, 320 further includes: a first pressure sensor configured to detect pressure measurement of input to the first fluid circuit of the heat transfer module 220, 230; a second pressure sensor configured to detect pressure measurement of input to the second fluid circuit of the heat transfer module 220, 230; a first pressure differential sensor across the input to output of the first fluid circuit of the heat transfer module 220, 230; a second pressure differential sensor across the input to output of the second fluidcircuit of the heat transfer module 220, 230; a first temperature sensor configured to detect temperature measurement of the input of the first fluid circuit of the heat transfer module 220, 230; a second temperature sensor configured to detect temperature measurement of the output of the first fluid circuit of the heat transfer module 220, 230; a third temperature sensor configured to detect temperature measurement of the input of the second fluid circuit of the heat transfer module 220, 230; a fourth temperature sensor configured to detect temperature measurement of the output of the second fluid circuit of the heat transfer module 220, 230; and a respective temperature sensor to detect temperature measurement of output of each heat exchanger 118 to each of the first fluid circuit and the second fluid circuit of the heat transfer module 220, 230, wherein the at least one controller is configured to receive data indicative of measurement from the first pressure sensor, the second pressure sensor, the first pressure differential sensor, the second pressure differential sensor, the first temperature sensor, the second temperature sensor, the third temperature sensor, and the fourth temperature sensor, for the optimizing.

[0297] In another example embodiment of any of the above, the heat transfer system 300, 320 further includes: a first flow sensor configured to detect first flow measurement of first flow through the first fluid circuit; and a second flow sensor configured to detect second flow measurement of second flow through the second fluid circuit, wherein the at least one controller is configured to: receive data indicative of the first flow measurement and the second flow measurement from the first flow sensor and the second flow sensor, calculate a respective heat load (Q) of the first flow through the heat transfer module 220, 230 and the second flow through the heat transfer module 220, 230 from: the first flow measurement, the second flow measurement, the respective temperature measurement from the first temperature sensor, the respective temperature measure from the third temperature sensor, and the respective temperature measurement from the respective temperature sensor of the output of each heat exchanger 118 to each of the first fluid circuit and the second fluid circuit, and wherein said optimizing is based on the respective heat load (Q) of the first flow and the respective heat load (Q) of the second flow.

[0298] In another example embodiment of any of the above, the heat transfer system 300, 320 further includes: at least one pressure sensor, temperature sensor, or flow sensor configured to detect measurement of the first fluid circuit and / or the second fluid circuit, wherein said optimizing is based on the measurement.

[0299] In another example embodiment of any of the above, said optimizing comprises determining that the measurement or a calculation or inference from the measurement reaches a threshold, and in response to said determining, increasing or decreasing a number of the valves 224 to be opened.

[0300] In another example embodiment of any of the above, said optimizing comprises mapping the measurement to a number of the valves 224 to be opened.

[0301] In another example embodiment of any of the above, the at least one pressure sensor, the temperature sensor, or the flow sensor is configured to detect measurement of at least one of the plurality of heat exchangers 118.

[0302] In another example embodiment of any of the above, the at least one pressure sensor, temperature sensor, or flow sensor is configured to detect measurement of a source supply or a system setpoint location.

[0303] In another example embodiment of any of the above, said optimizing comprises mapping a system variable or a system setpoint to a number of the valves 224 to be opened.

[0304] In another example embodiment of any of the above, the system variable or the system setpoint includes head demand, flow demand, or temperature demand.

[0305] In another example embodiment of any of the above, each heat exchanger 118 is a plate and frame counter current heat exchanger; a shell and tube heat exchange; or a gasketed plate heat exchanger.

[0306] In another example embodiment of any of the above, at least two of the heat exchangers 118 have a different dimension and a different capacity.

[0307] In another example embodiment of any of the above, at least two of the heat exchangers 118 have a same dimension and a same capacity.

[0308] Another example is a method for the heat transfer system 300, 320 as in any one of the above, the method being implemented by at least one controller and comprising: controlling the respective valve 224 to optimize at least one parameter of each of the heat exchangers 118.

[0309] Figure 9 illustrates an example method 1000 for selecting two or more of the heat exchangers 118 for operation in the building system 100, in accordance with an example embodiment. At least some of the method 1000 can be performed by the controller 116. At step 1002, the method 1000 includes the controller 116 determining a design setpoint of the building system 100. At step 1004, the method 1000 includes the controller 116 determining a load profile of the variable load of the building system 100. At step 1006, the method 1000 includes the controller 116 determining a plurality of candidate heat exchangers 118 that have not been installed in the building system 100 that each have respective capacity for operating in parallel in a staged manner to source the variable load according to the load profile. Each candidate heat exchanger 118 has at least one respective parameter affected by the variable load according to the load profile. At step 1008, the method 1000 includes the controller 116 calculating the at least one respective parameter for combinations of two or more of the candidate heat exchangers 118 operating in parallel in the staged manner in the building system 100 according to the load profile. At step 1010, the method 1000 includes selecting one of the combinations of the two or more candidate heat exchangers 118 which optimize the at least one respective parameter for the operating in parallel in the staged manner for installation in the system. In an example, the selecting can be automatically performed by the controller 116. In another example, the controller 116 can output through a graphical user interface the at least one parameter versus particular combinations of two or more candidate heat exchangers 118. A user can manually select one of the combinations of heat exchangers 118 in for purchasing, installation, and operation in the building system 100. At step 1012, the method 1000 includes installing and operating the selected combination of heat exchangers 119 in the building system 100. For example, the selected combination of the heat exchangers 118 can be operated in accordance with step 702 (Figure 7A).

[0310] In an example, at step 1014, one or more candidate control pumps 102a, 102b are determined to be candidate control pumps 102a, 102b for operation in thebuilding system 100. The at least one parameters of the candidate control pumps 102a, 102b are considered as part of the equation and part of step 1008, as part of the combination in the calculating of the at least one parameter for the building system 100. The one or more candidate control pumps 102a, 102b affect the at least one parameter of the candidate heat exchangers 118 in an interrelated manner within the building system 100. At step 1012, the one or more candidate control pumps 102a, 102b in the combination with the candidate heat exchangers 118 that is selected can then be purchased, installed and operated in the building system 100. For example, the selected combination of control pumps 102a, 102b and the heat exchangers 118 can be operated in accordance with step 702 (Figure 7A).

[0311] Another example embodiment is a method for a system having a variable load, the method being performed by at least one processor and comprising: determining a load profile of the variable load; determining a plurality of candidate heat exchangers 118 that have not been installed in the system that each have respective capacity for operating in parallel in a staged manner to source the variable load according to the load profile, each candidate heat exchanger 118 having at least one respective parameter affected by the variable load according to the load profile; calculating the at least one respective parameter for combinations of two or more of the candidate heat exchangers 118 operating in parallel in the staged manner in the system according to the load profile; and selecting one of the combinations of the two or more candidate heat exchangers 118 which optimize the at least one respective parameter for the operating in parallel in the staged manner for installation in the system.

[0312] In another example embodiment of any of the above, the load profile is for flow load or temperature load.

[0313] In another example embodiment of any of the above, the method further includes: determining one or more candidate variable flow control mechanical devices for operating with the two or more candidate heat exchangers 118 in the system based on the load profile, wherein the calculating includes calculating the at least one respective parameter for the combinations of the two or more candidate heat exchangers 118operating in the staged manner with the one or more candidate variable flow control mechanical devices.

[0314] In another example embodiment of any of the above, the one ore more candidate variable flow control mechanical devices comprise one or more variable control pumps or one or more pressure independent control valves.

[0315] In another example embodiment of any of the above, the at least one respective parameter of each of the two or more candidate heat exchangers 118 includes an affect of those two or more candidate heat exchangers 118 on operating cost of or pressure drop fulfillment by the one or more variable control pumps.

[0316] In another example embodiment of any of the above, the method further includes determining a design setpoint of the system, wherein the design setpoint affects the at least one parameter, wherein the calculating is further based on the design setpoint.

[0317] In another example embodiment of any of the above, the design setpoint is flow and head.

[0318] In another example embodiment of any of the above, the two or more candidate heat exchangers 118 of the one of the combinations that are selected have different of the respective capacity and a different respective dimension.

[0319] In another example embodiment of any of the above, the two or more candidate heat exchangers 118 of the one of the combinations that are selected have a same of the respective capacity and a same respective dimension.

[0320] In another example embodiment of any of the above, the method further includes performing the operating in the system of the one of the combinations of the two or more candidate heat exchangers 118 that are selected for the installation in the system.

[0321] In another example embodiment of any of the above, said performing the operating of the one of the combinations that is selected in the staged manner is by controlling a respective valve 224 for the two or more candidate heat exchangers 118 that are selected.

[0322] In another example embodiment of any of the above, said performing the operating comprises mapping a system variable or a system setpoint to a number of the two or more candidate heat exchangers 118 of the one of the combinations that are selected to be opened.

[0323] In another example embodiment of any of the above, the system variable or the system setpoint includes head demand, flow demand, or temperature demand.

[0324] In another example embodiment of any of the above, the at least one respective parameter of each of the two or more candidate heat exchangers 118 in the combinations includes: heat transfer efficiency; heat transfer coefficient (U); heat transfer capacity (Qc); flow value up to flow capacity; flow velocity value; pressure drop value; temperature load capacity, and / or fouling factor.

[0325] In another example embodiment of any of the above, the at least one respective parameter includes cost over part load operation, wherein the cost is based on operating cost and replacement cost.

[0326] In another example embodiment of any of the above, the optimizing the at least one respective parameter includes optimizing the at least one respective parameter over time.

[0327] In another example embodiment of any of the above, the optimizing the at least one respective parameter over time is over a time of life of each of the two or more candidate heat exchangers 118.

[0328] In another example embodiment of any of the above, the two or more candidate heat exchangers 118 are integrated in a heat transfer module 220, 230.

[0329] In another example embodiment of any of the above, the calculating is performed using a model or a machine learning model.

[0330] In another example embodiment of any of the above, the calculating of the respective combination is based on initial cost and operating cost over a payback period.

[0331] In another example embodiment of any of the above, the calculating of the respective combination includes iteratively calculating different combinations.

[0332] In another example embodiment of any of the above, the selecting is received through a graphical user interface.

[0333] Another example embodiment is a method performed by at least one controller to perform any one of the above.

[0334] Another example embodiment is a system, heat transfer system 300, 320, or building system 100, comprising at least one controller for performing the method of any one of the above.

[0335] Another example embodiment is a non-transitory computer readable medium having instructions stored thereon executable by at least one controller for performing the method of any one of the above.

[0336] In example embodiments, as appropriate, each illustrated block or module may represent software, hardware, or a combination of hardware and software. Further, some of the blocks or modules may be combined in other example embodiments, and more or fewer blocks or modules may be present in other example embodiments.Furthermore, some of the blocks or modules may be separated into a number of subblocks or sub-modules in other embodiments.

[0337] While some of the example embodiments are described in terms of methods, a person of ordinary skill in the art will understand that example embodiments are also directed to various apparatus such as a server apparatus including components for performing at least some of the aspects and features of the described methods, be it by way of hardware components, software or any combination of the two, or in any other manner. Moreover, an article of manufacture for use with the apparatus, such as a prerecorded storage device or other similar non-transitory computer readable medium including program instructions recorded thereon, or a computer data signal carrying computer readable program instructions may direct an apparatus to facilitate the practice of the described methods. It is understood that such apparatus, articles of manufacture, and computer data signals also come within the scope of the example embodiments.

[0338] While some of the above examples have been described as occurring in a particular order, it will be appreciated to persons skilled in the art that some of themessages or steps or processes may be performed in a different order provided that the result of the changed order of any given step will not prevent or impair the occurrence of subsequent steps. Furthermore, some of the messages or steps described above may be removed or combined in other embodiments, and some of the messages or steps described above may be separated into a number of sub-messages or sub-steps in other embodiments. Even further, some or all of the steps of the conversations may be repeated, as necessary. Elements described as methods or steps similarly apply to systems or subcomponents, and vice-versa.

[0339] In example embodiments, the one or more controllers can be implemented by or executed by, for example, one or more of the following systems: Personal Computer (PC), Programmable Logic Controller (PLC), Microprocessor, Internet, Cloud Computing, Mainframe (local or remote), mobile phone or mobile communication device.

[0340] The term "computer readable medium" as used herein includes any medium which can store instructions, program steps, or the like, for use by or execution by a computer or other computing device including, but not limited to: magnetic media, such as a diskette, a disk drive, a magnetic drum, a magneto-optical disk, a magnetic tape, a magnetic core memory, or the like; electronic storage, such as a random access memory (RAM) of any type including static RAM, dynamic RAM, synchronous dynamic RAM (SDRAM), a read-only memory (ROM), a programmable-read-only memory of any type including PROM, EPROM, EEPROM, FLASH, EAROM, a so-called "solid state disk", other electronic storage of any type including a charge-coupled device (CCD), or magnetic bubble memory, a portable electronic data-carrying card of any type including COMPACT FLASH, SECURE DIGITAL (SD-CARD), MEMORY STICK, and the like; and optical media such as a Compact Disc (CD), Digital Versatile Disc (DVD) or BLU-RAY (TM) Disc.

[0341] Variations may be made to some example embodiments, which may include combinations and sub-combinations of any of the above. The various example embodiments are merely examples and are in no way meant to limit the scope of the example embodiments. Variations of the innovations described herein will be apparent to persons of ordinary skill in the art having the benefit of the described examples, suchvariations being within the intended scope of the example embodiments. In particular, features from one or more of the above-described embodiments may be selected to create alternative embodiments comprised of a sub-combination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and sub-combinations would be readily apparent to persons skilled in the art upon review of the example embodiments as a whole. The subject matter described herein intends to cover all suitable changes in technology.

[0342] Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.

Claims

WHAT IS CLAIMED IS:

1. A heat transfer system, comprising:a plurality of heat exchangers in parallel configured for connection to a first fluid circuit and a second fluid circuit;a respective valve for each of the heat exchangers; andat least one controller configured to:control the respective valve to optimize at least one parameter of each of the heat exchangers.

2. The heat transfer system as claimed in claim 1 , wherein the at least one parameter of each of the heat exchangers includes:heat transfer efficiency;heat transfer coefficient (U);heat transfer capacity (Qc);flow value up to flow capacity;flow velocity value;pressure drop value;temperature load capacity, and / orfouling factor.

3. The heat transfer system as claimed in claim 1 , wherein the at least one parameter of each of the heat exchangers includes a coefficient value of each of the heat exchangers.

4. The heat transfer system as claimed in claim 1 , wherein the at least oneparameter includes cost over part load operation, wherein the cost is based on operating cost and replacement cost.

5. The heat transfer system as claimed in claim 1 , wherein the controlling the respective valve is in a staged manner.

6. The heat transfer system as claimed in claim 5, wherein the controlling the respective valve in the staged manner includes maximizing flow velocity for each of the plurality of heat exchangers having the respective valve that is open.

7. The heat transfer system as claimed in claim 1 , wherein the optimizing the at least one parameter includes optimizing the at least one parameter over time.

8. The heat transfer system as claimed in claim 7, wherein the optimizing the at least one parameter over time is over a time of life of each of the heat exchangers.

9. The heat transfer system as claimed in claim 1 , wherein the respective valve is a respective variable control valve.

10. The heat transfer system as claimed in claim 9, wherein the optimizing includes controlling at least one of the respective valve to a partially open state.

11. The heat transfer system as claimed in claim 1 , wherein the respective valve is a respective shutoff valve.

12. The heat transfer system as claimed in claim 1 , wherein the controlling the respective valve is performed during real time sourcing of a variable load.

13. The heat transfer system as claimed in claim 1 , wherein the controlling the respective valve includes opening only an individual one of the heat exchangers to flush a fouling of the individual one of the heat exchangers during real time sourcing of a variable load.

14. The heat transfer system as claimed in claim 1 , further comprising:first at least one variable control pump for providing variable flow of a firstcirculation medium through the first fluid circuit; andat least one flow control mechanical device for providing variable flow of a second circulation medium through the second fluid circuit,wherein the at least one controller is configured to control the first at least one variable control pump and the flow control mechanical device to perform the optimizing during real time sourcing of a variable load.

15. The heat transfer system as claimed in claim 14, wherein the controlling the first at least one variable control pump is to a first flow amount during the real time sourcing of the variable load in order to flush a fouling of each of the plurality of heat exchangers having the respective valve that is open.

16. The heat transfer system as claimed in claim 14, wherein the at least one flow control mechanical device includes second at least one variable control pump or a variable control valve.

17. The heat transfer system as claimed in claim 14, wherein the at least one parameter of each of the heat exchangers includes an affect of that heat exchanger on operating cost of or pressure drop fulfillment by the first at least one variable control pump.

18. The heat transfer system as claimed in claim 1 , wherein the controlling the respective valve includes opening less than all of the valves at a time.

19. The heat transfer system as claimed in claim 1 , wherein the at least one controller is located remote to the plurality of heat exchangers.

20. The heat transfer system as claimed in claim 1 , wherein the plurality of heat exchangers are integrated in a heat transfer module which is configured to be connected to the first fluid circuit and the second fluid circuit.

21. The heat transfer system as claimed in claim 20, wherein the at least one controller is integrated with the heat transfer module.

22. The heat transfer system as claimed in claim 20, wherein the at least one controller is separate from the heat transfer module.

23. The heat transfer system as claimed in claim 20, further comprising:a first pressure sensor configured to detect pressure measurement of input to the first fluid circuit of the heat transfer module;a second pressure sensor configured to detect pressure measurement of input to the second fluid circuit of the heat transfer module;a first pressure differential sensor across the input to output of the first fluid circuit of the heat transfer module;a second pressure differential sensor across the input to output of the second fluid circuit of the heat transfer module;a first temperature sensor configured to detect temperature measurement of the input of the first fluid circuit of the heat transfer module;a second temperature sensor configured to detect temperature measurement of the output of the first fluid circuit of the heat transfer module;a third temperature sensor configured to detect temperature measurement of the input of the second fluid circuit of the heat transfer module;a fourth temperature sensor configured to detect temperature measurement of the output of the second fluid circuit of the heat transfer module; anda respective temperature sensor to detect temperature measurement of output of each heat exchanger to each of the first fluid circuit and the second fluid circuit of the heat transfer module,wherein the at least one controller is configured to receive data indicative of measurement from the first pressure sensor, the second pressure sensor, the first pressure differential sensor, the second pressure differential sensor, the first temperaturesensor, the second temperature sensor, the third temperature sensor, and the fourth temperature sensor, for the optimizing.

24. The heat transfer system as claimed in claim 23, further comprising:a first flow sensor configured to detect first flow measurement of first flow through the first fluid circuit; anda second flow sensor configured to detect second flow measurement of second flow through the second fluid circuit,wherein the at least one controller is configured to:receive data indicative of the first flow measurement and the second flow measurement from the first flow sensor and the second flow sensor,calculate a respective heat load (Q) of the first flow through the heat transfer module and the second flow through the heat transfer module from: the first flow measurement, the second flow measurement, the respective temperature measurement from the first temperature sensor, the respective temperature measure from the third temperature sensor, and the respective temperature measurement from the respective temperature sensor of the output of each heat exchanger to each of the first fluid circuit and the second fluid circuit, andwherein said optimizing is based on the respective heat load (Q) of the first flow and the respective heat load (Q) of the second flow.

25. The heat transfer system as claimed in claim 1 , further comprising:at least one pressure sensor, temperature sensor, or flow sensor configured to detect measurement of the first fluid circuit and / or the second fluid circuit,wherein said optimizing is based on the measurement.

26. The heat transfer system as claimed in claim 25, wherein said optimizing comprises determining that the measurement or a calculation or inference from themeasurement reaches a threshold, and in response to said determining, increasing or decreasing a number of the valves to be opened.

27. The heat transfer system as claimed in claim 25, wherein said optimizing comprises mapping the measurement to a number of the valves to be opened.

28. The heat transfer system as claimed in claim 25, wherein the at least one pressure sensor, the temperature sensor, or the flow sensor is configured to detect measurement of at least one of the plurality of heat exchangers.

29. The heat transfer system as claimed in claim 25, wherein the at least one pressure sensor, temperature sensor, or flow sensor is configured to detect measurement of a source supply or a system setpoint location.

30. The heat transfer system as claimed in claim 1 , wherein said optimizing comprises mapping a system variable or a system setpoint to a number of the valves to be opened.

31. The heat transfer system as claimed in claim 30, wherein the system variable or the system setpoint includes head demand, flow demand, or temperature demand.

32. The heat transfer system as claimed in claim 1 , wherein each heat exchanger is a plate and frame counter current heat exchanger; a shell and tube heat exchange; or a gasketed plate heat exchanger.

33. The heat transfer system as claimed in claim 1 , wherein at least two of the heat exchangers have a different dimension and a different capacity.

34. The heat transfer system as claimed in claim 1 , wherein at least two of the heat exchangers have a same dimension and a same capacity.

35. A method for the heat transfer system as claimed in any one of claims 1 to 34, the method being implemented by at least one controller and comprising:controlling the respective valve to optimize the at least one parameter of each of the heat exchangers.

36. A method for a system having a variable load, the method being performed by at least one processor and comprising:determining a load profile of the variable load;determining a plurality of candidate heat exchangers that have not been installed in the system that each have respective capacity for operating in parallel in a staged manner to source the variable load according to the load profile, each candidate heat exchanger having at least one respective parameter affected by the variable load according to the load profile;calculating the at least one respective parameter for combinations of two or more of the candidate heat exchangers operating in parallel in the staged manner in the system according to the load profile; andselecting one of the combinations of the two or more candidate heat exchangers which optimize the at least one respective parameter for the operating in parallel in the staged manner for installation in the system.

37. The method as claimed in claim 36, wherein the load profile is for flow load or temperature load.

38. The method as claimed in claim 36, further comprising:determining one or more candidate variable flow control mechanical devices for operating with the two or more candidate heat exchangers in the system based on the load profile,wherein the calculating includes calculating the at least one respective parameter for the combinations of the two or more candidate heat exchangers operating in the staged manner with the one or more candidate variable flow control mechanical devices.

39. The method as claimed in claim 38, wherein the one ore more candidate variable flow control mechanical devices comprise one or more variable control pumps or one or more pressure independent control valves.

40. The method as claimed in claim 39, wherein the at least one respective parameter of each of the two or more candidate heat exchangers includes an affect of those two or more candidate heat exchangers on operating cost of or pressure drop fulfillment by the one or more variable control pumps.

41. The method as claimed in claim 36, further comprising determining a design setpoint of the system, wherein the design setpoint affects the at least one parameter, wherein the calculating is further based on the design setpoint.

42. The method as claimed in claim 41 , wherein the design setpoint is flow and head.

43. The method as claimed in claim 36, the two or more candidate heat exchangers of the one of the combinations that are selected have different of the respective capacity and a different respective dimension.

44. The method as claimed in claim 36, the two or more candidate heat exchangers of the one of the combinations that are selected have a same of the respective capacity and a same respective dimension.

45. The method as claimed in claim 36, further comprising performing the operating in the system of the one of the combinations of the two or more candidate heat exchangers that are selected for the installation in the system.

46. The method as claimed in claim 45, wherein said performing the operating of the one of the combinations that is selected in the staged manner is by controlling a respective valve for the two or more candidate heat exchangers that are selected.

47. The method as claimed in claim 45, wherein said performing the operating comprises mapping a system variable or a system setpoint to a number of the two or more candidate heat exchangers of the one of the combinations that are selected to be opened.

48. The method as claimed in claim 47, wherein the system variable or the system setpoint includes head demand, flow demand, or temperature demand.

49. The method as claimed in claim 36, wherein the at least one respective parameter of each of the two or more candidate heat exchangers in the combinations includes:heat transfer efficiency;heat transfer coefficient (U);heat transfer capacity (Qc);flow value up to flow capacity;flow velocity value;pressure drop value;temperature load capacity, and / orfouling factor.

50. The method as claimed in claim 36, wherein the at least one respective parameter includes cost over part load operation, wherein the cost is based on operating cost and replacement cost.

51. The method as claimed in claim 36, wherein the optimizing the at least one respective parameter includes optimizing the at least one respective parameter over time.

52. The method as claimed in claim 51 , wherein the optimizing the at least one respective parameter over time is over a time of life of each of the two or more candidate heat exchangers.

53. The method as claimed in claim 36, wherein the two or more candidate heat exchangers are integrated in a heat transfer module.

54. The method as claimed in claim 36, wherein the calculating is performed using a model or a machine learning model.

55. The method as claimed in claim 36, wherein the calculating of the respectivecombination is based on initial cost and operating cost over a payback period.

56. The method as claimed in claim 36, wherein the calculating of the respective combination includes iteratively calculating different combinations.

57. The method as claimed in claim 36, wherein the selecting is received through a graphical user interface.

58. A controller configured to performing the method as claimed in any one of claims 35 to 57.

59. A non-transitory computer readable medium having instructions stored thereon executable by the at least one controller for performing the method as claimed in any one of claims 35 to 57.

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